SOUTHERN LUZON STATE UNIVERSITY PRELIM S.Y.

2020-2021
COLLEGE OF ENGINEERING
MECHANICAL ENGINEERING DEPARTMENT MCE03 WORKSHOP THEORY AND PRACTICE >>> 1

C O L L E G E O F ENGINEERING

Prepared By: Engr. J.D.Campita | Engr. Ronnel Nombrefia

 SOUTHERN LUZON STATE UNIVERSITY PRELIM S.Y. 2020-2021
COLLEGE OF ENGINEERING
MECHANICAL ENGINEERING DEPARTMENT MCE03 WORKSHOP THEORY AND PRACTICE >>> 2

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What Is This Module About?

Welcome to the course of Shielded Metal Arc Work (SMAW)

The Welding NC I (SMAW) Qualification consists of competencies that a person

must achieve to weld carbon steel plates components as specified by layout, blueprints, diagrams,
work order, welding procedure or oral instructions using SMAW welding equipment.

This Qualification conforms with AWS D 1.1 Structural Welding Code; ASME IX Boiler
and Pressure Vessel Code; API 1104 Code for Gas and Oil Pipeline Facilities; and ISO
9606-1 Qualification of Welders for Steel.
The Units of Competency comprising this qualification include the following:
Code No. BASIC COMPETENCIES
5 00 311 1 01 Receive and respond to workplace communication
5 00 311 1 02 Work with others
5 00 311 1 03 Demonstrate work values
5 00 311 1 04 Practice basic housekeeping procedures

Code No. COMMON COMPETENCIES

MEE721201 Apply Safety Practices
MEE721202 Interpret Drawings and Sketches
MEE721203 Perform Industry Calculations
MEE721204 Contribute to Quality System
MEE721205 Use Hand Tools
MEE721206 Prepare Weld Materials
MEE721207 Setup Welding Equipment
MEE721208 Fit up Weld Materials
MEE721209 Repair Welds

Code No. CORE COMPETENCY

MEE721301 Weld Carbon Steel Plates Using SMAW
A person who has achieved this Qualification is competent to be:
- Plate Welder (SMAW)

Prepared By: Engr. J.D.Campita | Engr. Ronnel Nombrefia

 SOUTHERN LUZON STATE UNIVERSITY PRELIM S.Y. 2020-2021
COLLEGE OF ENGINEERING
MECHANICAL ENGINEERING DEPARTMENT MCE03 WORKSHOP THEORY AND PRACTICE >>> 3

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CORE COMPETENCIES

UNIT OF COMPETENCY : Weld Carbon Steel Plates Using SMAW

UNIT CODE : MEE721301
DESCRIPTOR : This unit covers the skills, knowledge and
attitudes in welding carbon steel plates
using SMAW process

ELEMENTS PERFORMANCE CRITERIA

Italicized terms are elaborated in the Range of Variables
1. Perform root pass 1.1 Root pass is performed in accordance with WPS
and/or client specifications.
1.2 Task is performed in accordance with company or
industry requirement and safety procedure.
1.3 Weld is visually checked for defects and repaired, as
required
1.4 Weld is visually acceptable in accordance with
applicable codes and standards
2. Clean root pass 2.1 Root pass is cleaned and free from defects and
discontinuities
2.2 Task is performed in accordance with approved WPS
3. Weld subsequent/ 3.1 Subsequent/ filling passes is performed in
filling passes accordance with approved WPS
3.2 Weld visually is checked for defects and repaired, as
required
3.3 Weld is visually acceptable in accordance with
applicable codes and standards
4. Perform capping 4.1 Capping is performed in accordance with approved
WPS and/or client specifications
4.2 Weld is visually checked for defects and repaired, as
required
4.3 Weld is visually acceptable in accordance with
applicable codes and standards

TRAINING STANDARDS

These guidelines are set to provide the Technical and Vocational Education and Training
(TVET) providers with information and other important requirements to consider when designing
training programs for SHIELDED METAL ARC WELDING (SMAW).

This includes information on curriculum design; training delivery; trainee entry

requirements; tools and equipment; training facilities; and trainers qualification, among others.

Prepared By: Engr. J.D.Campita | Engr. Ronnel Nombrefia

 SOUTHERN LUZON STATE UNIVERSITY PRELIM S.Y. 2020-2021
COLLEGE OF ENGINEERING
MECHANICAL ENGINEERING DEPARTMENT MCE03 WORKSHOP THEORY AND PRACTICE >>> 4

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CURRICULUM DESIGN

Course Title: SHIELDED METAL ARC WELDING NC Level I

Suggested Nominal Training Hours: 28 hrs. ( Basic Competencies)
56 hrs. ( Common Competencies)
184 hrs. ( Core Competencies)

Course Description:

This course is designed to enhance the knowledge, skills and attitudes in Shielded Metal
Arc Welding in accordance with industry standards. It c overs core competencies such as Setting-
up Welding Equipment, Preparing Weld Materials, Fitting up Weld Materials, Welding Carbon
Steel Plates Using SMAW and Repairing Weld

BASIC COMPETENCIES

Unit of Learning Outcomes

Competency
1. Receive and respond to 1.1 Follow routine spoken message
workplace communication 1.2 Perform work duties following written notices.
2.1 Develop effective workplace relationship.
2. Work with others
2.2 Contribute to work group activities.
3.1 Define the purpose of work
3.2 Apply work values/ethics
3. Demonstrate work values
3.3 Deal with ethical problems
3.4 Maintain integrity of conduct in the workplace
4.1 Sort and remove un necessary items
4.2 Arrange items
4. Practice housekeeping
4.3 Maintain work areas, tools and equipment
procedures
4.4 Follow standardize work process and procedures
4.5 Perform work spontaneously

Prepared By: Engr. J.D.Campita | Engr. Ronnel Nombrefia

 SOUTHERN LUZON STATE UNIVERSITY PRELIM S.Y. 2020-2021
COLLEGE OF ENGINEERING
MECHANICAL ENGINEERING DEPARTMENT MCE03 WORKSHOP THEORY AND PRACTICE >>> 5

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COMMON COMPETENCIES
Unit of
Learning Outcomes
Competency
1. Apply Safety Practices 1.1 Identify hazardous areas
1.2 Use protective clothing and devices
1.3 Perform safe handling of tools, equipment and
materials
1.4 Perform first aid
1.5 Use fire extinguisher
2. Interpret working 2.1 Identify standard alphabet of lines
drawings and sketches 2.2 Identify orthographic/ isometric views
2.3 Interpret standard drawing symbols, dimensional
tolerances and notations
3. Perform Industry 3.1 Perform four fundamental operations
Calculations 3.2 Perform conversion of units
3.3 Perform calculations on algebraic expressions
3.4 Compute percentage and Ratio
4. Contribute to quality 4.1 Inspect work done
System 4.2 Apply quality standards to work
4.3 Protect company property and customer interest
5. Use hand tools 5.1 Select hand tools
5.2 Use hand tools
5.3 Maintain hand tools
6. Prepare Weld Materials 6.1 Set-up cutting equipment
6.2 Cut and prepare edge of materials
6.3 Clean surfaces and edges
6.4 Prepare welding consumables
6.5 Prepare welding safety and protective equipment
7. Set-up Welding 7.1 Set up welding machine
Equipmen 7.2 Set up welding accessories
7.3 Set up welding positioners, jigs and fixtures
7.4 Set up pre-heating tools/equipment as required
8. Fit up Weld Materials 8.1 Perform tack welding
8.2 Check gap and alignment
8.3 Set up welding positioner
9. Repair Welds 9.1 Mark/locate weld defects
9.2 Prepare tools and equipment
9.3 Remove defects
9.4 Perform re-welding

Prepared By: Engr. J.D.Campita | Engr. Ronnel Nombrefia

 SOUTHERN LUZON STATE UNIVERSITY PRELIM S.Y. 2020-2021
COLLEGE OF ENGINEERING
MECHANICAL ENGINEERING DEPARTMENT MCE03 WORKSHOP THEORY AND PRACTICE >>> 6

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TRAINEE ENTRY REQUIREMENTS
Trainees or students wishing to gain entry into this course should possess the following
requirements:
 can communicate either oral and written
 physically and mentally fit
 with good moral character
 can perform basic mathematical computation

NATIONAL CERTIFICATE (NC) is a certification issued to individuals who achieved

all the required units of competency for a national qualification as defined under the Training
Regulations. NCs are aligned to specific levels within the PTQF. (TESDA Board Resolution
No. 2004-13, Training Regulations Framework)

NATIONAL CERTIFICATE LEVEL refers to the four (4) qualification levels

defined in the Philippine TVET Qualifications Framework (PTQF) where the worker
with:

a. NCI performs a routine and predictable tasks; has little judgment; and, works
under supervision;
b. NC II performs prescribed range of functions involving known routines
and procedures; has limited choice and complexity of functions, and has
little accountability;

Prepared By: Engr. J.D.Campita | Engr. Ronnel Nombrefia

 SOUTHERN LUZON STATE UNIVERSITY PRELIM S.Y. 2020-2021
COLLEGE OF ENGINEERING
MECHANICAL ENGINEERING DEPARTMENT MCE03 WORKSHOP THEORY AND PRACTICE >>> 7

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LEARNING OUTCOMES:
At the end of this Lesson, you are expected to
do the following:

 Familiarization of tools and equipment

 Follow standardize work process and procedures

 Perform work spontaneously

Prepared By: Engr. J.D.Campita | Engr. Ronnel Nombrefia

 SOUTHERN LUZON STATE UNIVERSITY PRELIM S.Y. 2020-2021
COLLEGE OF ENGINEERING
MECHANICAL ENGINEERING DEPARTMENT MCE03 WORKSHOP THEORY AND PRACTICE >>> 8

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Definition of Terms
 Adjustable wrench- a tool with movable jaw which makes it adjustable to
various sizes of nuts

 Ball peen hammer- a tool for straightening bending and deforming metals

 Chipping hammer- used for removing slag on weld and with two faces, the
tapered from one side and round pointed on the other side

 Cold chisel- a wedge-shaped tool used to shear, cut and chip metal

 Files- made of high grade steel hardened and tempered. A file has rows of teeth
that form, shape and finish metal by removing small chips and smoothing rough
edges of the metal surface

 Hacksaw - a tooth- cutting tool usually with a solid and adjustable frame

 Lubricating- a process of maintenance wherein oil is put in between moving parts of a

tool or equipment to prevent the tool from rust or damage

 Micrometer caliper- a precision measuring instrument used to measure

dimensions in thousandths of an inch

 Pliers- a tool for holding, cutting and twisting wires

 Punches-tools- used for permanent marking on surface of metal

 Scraper-tool for removing points, burrs,and sharp edges from metal surface

 Screw driver- a hand tool that is designed to turn screws. The blade is made of
steel, attached to one end of which a wooden or plastic handle

 Tightening/ loosening- a process where tools and equipment are adjusted based
on standard procedure

 Try square- an instrument used to measure the squareness of an object

 Vernier caliper- a precision measuring instrument used to measure the inside,

outside diameter, as well as depth of hole and slo
 Wrench- used for loosening and tightening light and heavy nuts and bolts

Prepared By: Engr. J.D.Campita | Engr. Ronnel Nombrefia

 SOUTHERN LUZON STATE UNIVERSITY PRELIM S.Y. 2020-2021
COLLEGE OF ENGINEERING
MECHANICAL ENGINEERING DEPARTMENT MCE03 WORKSHOP THEORY AND PRACTICE >>> 9

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LEARNING OUTCOME

Select and classify hand tools and equipment

PERFORMANCE STANDARDS

 Hand tools selected are appropriate to the requirements of the task.

 Unsafe or defective tools are identified and marked for repair according to
procedure.

What Do You Already Know?

Let us determine how much you already know about selecting and classifying tools and
equipment. Take this test.

I. Directions: Match Column A with Column B. Write only the letter of the
correct answer before each number.
COLUMN A COLUMN B
_____1.A measuring tool used to measure squareness of an object.
_____2.Tools used for measuring or setting of distances, and to a. Hacksaw
lay out arcs and circles. b. Cold chisel
c. Try Square
_____3.Rectangular in shape and tampered slightly in width and d. Flat file
thickness. It is the most commonly used files for general work. e. Divider
_____4.It is used for chipping flat surfaces, cutting of rivets or
metal fasteners, thin sheets, small bars; and for general purposes.
_____5.The most common tool used in tool room. It is made of
tampered steel about 1/8 inch thick and ¾ inch wide and 6 to 12
inches long.

Prepared By: Engr. J.D.Campita | Engr. Ronnel Nombrefia

 SOUTHERN LUZON STATE UNIVERSITY PRELIM S.Y. 2020-2021
COLLEGE OF ENGINEERING
MECHANICAL ENGINEERING DEPARTMENT MCE03 WORKSHOP THEORY AND PRACTICE >>> 10

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Multiple Choice - Directions: Encircle the letter of the correct answer.

1. A tooth cutting tool usually with the solid and adjustable frame.
A. Hacksaw B. Screw driver
B. Hammer D. Wrench

2. Tool used for loosening and tightening light and heavy nuts and bolts.
A. Hacksaw B. Screw driver
C. Hammer D. Wrench

3. This tool is used to tighten and loosen screws by pushing or pulling screws in a
rotating manner.
A. Hacksaw B. Screw driver
C. Hammer D. Wrench

4. A tooth cutting tool usually with the solid and adjustable frame.
A. Hacksaw B. Screw driver
B. Hammer D. Wrench

5. Tool used for loosening and tightening light and heavy nuts and bolts.
A. Hacksaw B. Screw driver
B. Hammer D. Wrench

6. This tool is used to tighten and loosen screws by pushing or pulling screws in
a rotating manner.
A. Hacksaw B. Screw driver
B. Hammer D. Wrench

A list of common hand tools and their uses are provided with picture illustration
for your better comprehension.
Hand tools are classified into four:
1. Measuring tools
2. Cutting tools
3. Driving tools and
4. Holding tools

Each classification has different types and uses.

Prepared By: Engr. J.D.Campita | Engr. Ronnel Nombrefia

 SOUTHERN LUZON STATE UNIVERSITY PRELIM S.Y. 2020-2021
COLLEGE OF ENGINEERING
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MEASURING TOOLS

 Pull-push rule. This flexible rule when extended

will support itself, but may also be used to measure
curved, irregular surfaces. Steel tape rule blade is
usually ½ inch wide and 72 inches long. The
graduation is sixteenths, except for the first 6 inches
which are graduated in thirty-seconds of an inch.

 Steel tape is similar to a steel tape rule except for its

flexible number of feet that are marked on the tape.
The tape is 3/8 inch wide and available in lengths from
25 to 100 feet.

 Steel rule. This is the most common tool used in

tool room. It is made of tampered steel about 1/8
inch thick and ¾ inch wide and 6 to 12 inches long.
The same style maybe obtained in length from 1 to
48 inches.

Try square is an instrument used to measure the

square of an object.

Prepared By: Engr. J.D.Campita | Engr. Ronnel Nombrefia

 SOUTHERN LUZON STATE UNIVERSITY PRELIM S.Y. 2020-2021
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Combination square. It is an instrument combined with

45°, 90° and a protractor.

Micrometer caliper. Is a precision measuring

instrument used to measure dimensions in
thousandths of an inch.

Micrometer caliper. Is a precision measuring

instrument used to measure dimensions in
thousandths of an inch.

Vernier caliper is a precision measuring instrument

used to measure the inside, outside diameter, as well
as depth of hole and slot.

Dividers. These are used for measuring or setting of distances,

and to lay out arcs and circles.

Prepared By: Engr. J.D.Campita | Engr. Ronnel Nombrefia

 SOUTHERN LUZON STATE UNIVERSITY PRELIM S.Y. 2020-2021
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CUTTING TOOLS

1. Hacksaw is a tooth cutting tool usually with a solid and adjustable frame. The main
parts are handles, blade, tightening screw and nuts. The tool is mainly used in cutting
metals like plates, pipes, rods, bars, angular, etc. but of minimal thickness, width and
length. Sometimes this tool is used for cutting plastic pipes and other materials that
suit to its purpose.

o Frame. It is the main body of the hacksaw

which holds the blade. The different types of
frames are the following:
a. Fixed or solid frames are intended to
hold only one size of blade at about 10 inches
long
b. Adjustable frame is frame that can be
adjusted to hold blades of different sizes such as
10, 12 and 14 inches in length.

Blade. It is made of thin, high grade steel usually

1.27 mm thick and 30.48cm long with an
inclined row of teeth serving as cutter.

The two types of blades are:

a. All hard In this type, the entire blade is hardened and tempered, making
it very brittle. Use this type in cutting steel and cast iron.

b. Flexible back. In this type, only the teeth portion is hardened and
tempered, making the blade springy and less likely to break.

The following are the recommended teeth-per-inch of blades for different kinds
of stocks to be cut:
a. 14 teeth-per-inch. It is used for brass, aluminum, cast iron and soft iron.
b. 18 teeth-per-inch. It is used for drill rod, mild steel, tool steel and general work
c. 24 teeth-per-inch. It is recommended for thin tubing and pipe.

Files are made of high grade steel which are hardened and tempered. Each file has
rows of teeth that form, shape and finish metal by removing small chips and
smoothing rough edges of the metal surface. They differ in length, shape, cut and
coarseness.

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SOUTHERN LUZON STATE UNIVERSITY PRELIM S.Y. 2020-2021
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Kinds of files:

1. Mill file a single-cut file used for filing and

finishing brass and bronze.

2. Flat file is usually rectangular in shape and

tapered slightly in width and thickness. It is one
of the most commonly used files for general work.

3. Square file is intended for filing square or

rectangular holes.

4. Round file is used primarily for enlarging

holes.

5. A triangular file is used for filing surfaces that

meet at least 90º. It is exclusively used for
sharpening wood saws and for smoothening
rectangular opening. It is also known as three-
square file.

Prepared By: Engr. J.D.Campita | Engr. Ronnel Nombrefia

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Cold chisel. A wedge-shaped tool used to shear, cut, and chip metal

Types of cold chisel and their particular functions:

1. Flat chisel is used for chipping flat

surfaces; cutting off rivets or metal
fasteners, thin sheets, and small bars; and
for general purposes. Its cutting edge
ranges from 13 to 25mm.

2. Cape chisel has a narrow edge suited for

cutting narrow grooves or slots.

3. Diamond-point chisel has a diamond-

shaped cutting edge intended to cut V- grooves.

4. Round-nose chisel has a round nose cutting

edge for cutting round and semi-circular
grooves.

 Scraper is used in removing points, burrs and

sharp edges from metal surface and similar
parts.

 Punches. are used for permanent

marking on the surface of metal.

Prepared By: Engr. J.D.Campita | Engr. Ronnel Nombrefia

 SOUTHERN LUZON STATE UNIVERSITY PRELIM S.Y. 2020-2021
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DRIVING TOOLS

Hammers
Ball peen hammer is used for straightening bending and
deforming metals. It has two faces. One is flat in striking
cold chisels and punches. The other side the “peen” is
rounded for bending and shaping metals.

.
Chipping hammer is used for removing slag on weld
and with two faces, the tapered from one side and
round pointed on the other side.

Wrench is used for loosening and tightening light and heavy nuts and
bolts. There are different kinds and sizes of wrenches designed according to
uses and functions.
An adjustable wrench has a movable jaw which
makes it adjustable to various sizes of nuts. A
heavy type of adjustable wrench is the
monkey/pipe wrench.

Oxy acetylene wrench- A type of wrench used for

tightening hose and fitting connection on oxy-acetylene
unit.

An open-ended wrench is one that is made to fit one size of nut or bolt
This is the most inexpensive type of wrench that is quite efficient in
ordinary situations.

Single-ended

Double-ended

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 SOUTHERN LUZON STATE UNIVERSITY PRELIM S.Y. 2020-2021
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Socket wrench is a tool with a usually

interchangeable socket to fit over a nut or bolt.

Screwdriver is hand tool that is designed to turn screws. The blade is made of steel,
attached to one end of a wooden or plastic handle. The other end is flattened to fit
slots in the heads of screws on bolts. The other kinds of screw drivers are called a
Phillips screw driver and helical-ratchet screw driver.

Phillips Flattened Helical-ratchet

HOLDING TOOLS

Clamps are made of different sizes and appearance that are fitted to its purpose.
These devices have been designed to hold work securely which performing skills
through grinding, bending, fitting and cutting of metals. Some types of clamps and
metal vises are:

Tool maker clamp is used for holding small parts

both at the bench and at the machine. This tool is
also known as a parallel clamp.

C-Clamp is an all-purpose clamp that is generally

used for all kinds of work.

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Drill vise is a sturdy steel vise with movable jaw that

easily goes back or forth by raising the handle.

Machinist vise is a work holding tool for

machining activity.

Vise Grip is a tool used to grip the stock tight

enough to hold the object.

Diagonal cutting pliers sometimes called side

cutting pliers. They are design for cutting wire and
thin metal

Long nose pliers used to hold a small object,

especially in electrical work

Pliers used mainly for twisting and cutting wire

Prepared By: Engr. J.D.Campita | Engr. Ronnel Nombrefia

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Defective and Non-Defective Hand tools

Introduction:
There are many ways of identifying hand tools. One of these is to identify them
according to their function. However, awareness of defective and non-defective hand
tools is a primordial concern of workers/welders to be effective in their jobs.
Below are the recommended practices to identify defective and non-defective hand
tools.
1. Visual inspection:

Defective tools can easily be distinguished from the functional ones through
visual inspection. The physical appearance of tools will describe such characteristics as
dullness, sharpness, dismantled parts, and unevenness of the teeth of the cutting tools.
2. Functionality:

Another way is to check the quality of the manufactured tools. Is it already

susceptible to wear and tear? Has it already exceeded its service life? Has it passed the
manufacturer‟s quality control test?

A few pieces of the hand tools issued in the shop can be

subjected for Condemnation they are no longer serviceable.
Some hand tools issued for years in shops and few pieces of these can be subjected
for condemnation.

3. Performance:

Performance of hand tools is determined not only during the actual use but also after
use to find out whether the hand tools are still worth using.

4. Service span:

Hand tools are issued to shop teacher at one time. However, this must be recorded
to determine when it was received and how long the tools have been kept in the shop. A
hand tool which is too old is unsafe for both the students and workers. Such tool should
be marked defective and segregated from the good ones.

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How Much Have You Learned?

Self-Check 1.1

Directions: Read the question carefully and write only the letter of the correct answer before
each number. No erasure

A. Diagonal Cutting Pliers B. Open end wrench C. Claw Hammer

D. C -Clamp E. Caliper F. Ball Peen Hammer

________1. One face is used to strike cold chisels and punches; the other face is for shaping
soft metal
________2. It is every accurate measurement, are available for outside and inside measurement.
________3. Tools good for small jobs and when a clamp is needed in a localized area
________4. Mark cutting or layout line between two points.
________5. The most commonly used hammer. The curved claw provides lever age for pulling
nails.
________6. Type of wrench has different size opening at each end
________7. Sometimes called side cutting pliers. They are designed for cutting wire and thin
metal.

How Much Have You Learned?

Direction: Choose the letter of the correct answer.

1. Defective hand tools are kept and .

A) marked as defective.
B) mixed together with non-defective tools.
C) put anywhere in the shop.
D) sold in the junk shop

2. One way of checking whether hand tools are defective or non-defective is the _____.
1.length of service
11. trade mark of the manufacturer
111. physical appearance

A. 1 only C. 111 only

B. 11 only D. 1, 11, and 111

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3. Which is determined after the operation of a hand tool is tested ?

A. Service span C.. Performance
B. Physical appearance D. Repair Maintenance

4.All defective hand tools with major defects are subjected to .

1. Repair
11. Condemnation
111. Display/sample

A. 1 only C. 111 only

B. 11 only D. 1, 11, and 111

5.Service span of a tool pertains to .

A) maintenance schedule
B) determining when the tool is acquired
C) functionality of a tool
D) defectiveness of a tool

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What Do You Need To Know?

Procedures on using different hand tools and equipment

Hacksaw

Steps in Mounting Blade to the Metal Frame

TEETH

1. Select the correct type of blade.

2. Attach the blade to the frame by pointing the teeth away from the handle.
3. Tighten the wing nut of the handle until the blade is tight enough.

Safety Measures:

Tighten the wing nut securely enough to prevent from buckling and breaking .
Steps in Fixing Stock In Metal Vise and Operation Position

25-30 cm
1. Fasten the stock in vise with lay-out line as close as possible to the end of the used vise
jaws.
2. Stand with your feet 25 to 30 centimeters apart and one foot forward.
3. Lean the body a little forward as shown in the drawing

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Steps in Sawing the Stock

1. Start the saw by guiding the blade with
the thumb of your left hand while taking
one or two light strokes with your right
hand.
2. Move the saw with a light steady and
even motion of about 40 to 50 strokes
per minute.
3. Apply pressure during the forward
stroke and release during the return
strokes.
4. Hold the stock with your left hand to
avoid cuts upon sawing with your right
hand
Steps in Bending 90o with Ball Peen Hammer

1. Force the metal over the vise jaws using

left-hand.
2. Strike it several times near the hand with
flat head of a hammer.

Steps in Squaring off a 90 o Bend

3. Place the metal in the bench vise and tighten

strongly.
4. Strike the metal with the flat head of a hammer in the
direction of the arrow indicated.

Circular Bend

1. Place the metal over a pipe or round bar and clamp in

a bench vise.
2. Strike the metal with a glancing blow using the flat
head of a hammer until the desired curve is obtained.

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Cold Chisel

Cold Chisel is used for cutting and chipping cold

metals.

The illustration above presents the Two Hands Positioning in cold chiseling which shows
the proper grip in using the tool. For heavy work, hand gripping of tool should be strong and tight;
for fine and small work, hold the tool lightly.

Look at the person work with the ball peen hammer and the chisel, as shown in the
illustration above. A cold chisel will cut metals only if you strike it with the flat head of a ball
peen hammer. The complete safety protection device and the body position when performing the
task (chiseling) are evidently done.

Wrench

Wrench is used for loosening and tightening light and

heavy nuts and bolts. There are various kinds and sizes of
wrenches designed according to use and function. It is tool
steel on movable jaws.

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A repair worker often uses tools to remove and replace damaged parts. The
wrenches are used to tighten and loosen the nut and bolts that hold the parts in place.
Other tools are used to hold parts for cutting, welding and other works.

Wash type of wrench is usually used for only one or two different jobs. Figure above
shows a repair worker using a box of wrench and an open-end wrench to remove a deck lid
bolt in an automobile. The ends of the wrench are offset (the hand is lower than the handle).
In this way, the worker‟s hand is above the surface of any object as the nut of bolt is turned.
A combination wrench of open-end and a box-end will tell the advantage of box-end over
open lid. Box-end wrench has complete contact with six points on the bolt head. This completely
surrounds the grip of the bolt head or nut allowing less chances of wrench slippage.

Screw Drivers

Cross Head Flat Head

Screw drivers are usually made in different sets. This tool is used to tighten and loosen
screws by pushing or pulling screws in a rotating manner. In the above illustration, a set of
standard and Phillips tips of different sizes are shown.Screwdriver is driven by fully turning
the blade in clockwise motion until the entire screw is removed from the wood and metal. The
purpose is to hold or fix two pieces and by no chances to space apart even opposing force occurs.

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How Much Have You Learned?

I. List two (2) don‟ts in the use of :

a. Hacksaw
________________________________________________________________
________________________________________________________________

b. bench vise
_______________________________________________________________
_______________________________________________________________

c. ball pern hammer

________________________________________________________________
________________________________________________________________

d. Chisel
________________________________________________________________
________________________________________________________________

e. Wrench
_________________________________________________________________
_________________________________________________________________

f. Screw drivers
____________________________________________________________________
______________________________________________________________

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How Do You Apply What You Have Learned?

(Demonstration)
Direction: Demonstrate the use of the tools in Self-Check 2.1 then use the checklist below as
basis for judging whether you meet the required competency. Write yes or no on separate answer
sheet.
Yes No
1. Can select correct type of blade of a hacksaw.
2. Can move the body a little forward while sawing the metal.
3. Can apply pressure during forward stroke and release in return while
sawing.

4. Can strike the metal with flat head of a hammer.

5. Can use wrench in loosening and tightening nuts and bolts.
6. Can use types of screw drivers correctly.
7. Can perform actual operations of hand tools by following safety
practices.

8. Can hold cold chisel properly while hammering with a hammer.

9. Can follow steps in rounding stock with the use of a hammer.
10. Can assemble and disassemble properly some movable hand tools.

Overall: Did the student meet the standard requirements?

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LEARNING OUTCOME
Maintain hand tools

PERFORMANCE STANDARDS
 Routine maintenance of hand tools is undertaken according to standard
operating procedures, principles and techniques.
 Hand tools are stored in designated location in accordance with manufacturer’s
instruction or standard operating procedure

1. ROUTINE MAINTENANCE

Maintenance of hand tools and machines are both primordial concerns of a repair
technician in the welding shops and/or in the welding production. The activities should
be on schedule and with proper coordination with the production people. The term
“repair” and “maintenance” works mean differently. Repair, unusually focuses on the
program of works done in the operation of power plants in machines that are in trouble
of stopping its function. While the term “maintenance” means a scheduled or a planned
visit of tools or equipments for inspection and from there, reports and recommendation
developed and the next tasks to be decided such as cleaning, application of lubricants,
dismantling and etc.

Some of the simple maintenance activities for hand tools, and the maintenance
schedule should be posted in a visible corner of the shop where
everybody can read it.

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 Lubricating. A task performed in the shop/production. Through the application

of lubricant substance to the identified items in parts like barrels, rollers, springs,
bearing, bolts and nuts, and other automotive parts.

 Tightening/Loosening. In an assembly of structures, we have tools for fittings

that need to be tightened and loosened and in as much as they pose high risk to
safety. Tightening bolts and nuts and other fittings requires procedures should
carried out compliance.

 Tool for hand Sharpening. Some tools need to be sharpened such as blades of
knife, cold chisel, punches and many others. To do hand sharpening for hand tools
requires techniques and application. In some multi knives cutter, manufacturers
produce knife sharpening system to hold or clamp the blade for ensuring strong
blade to stone contact during sharpening and also provided with course to fine
honing stones. For cold chisel and punches, the right file-size and grades are used
for repairing the defective anvil curve.

 Simple Repair. Repair practices of hand tools are still available anytime. But, to
some extent, tools are checked yearly and many of the hand tools are eligible for
condemnation and the whole items are to be replaced by a new unit. However,
there are instances that minor repair can be performed, like replacement of
wooden handle of a hammer and mushroomed head of a cold chisel

 Cleaning. Simple process applied to hand tools. The cleaning approach may differ from
one another. For example, cleaning of the rack corners of hand tools by using air vacuum
or by a piece of clothes. Similar process may be applied to identical cleaning situations.

By piece of cloth By air vacuum

2. PROPER STORAGE OF HAND TOOLS/EQUIPMENT

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(5S Implementation)
 Clearly label machinery, equipment, part, jigs, tools, and their locations, so
that everything is understandable, and visible to everyone at a glance.
 Don‟t pile up jigs, tools, and materials without separators (shelves). They
should be picked up easily.
 Rearrange machinery and equipment to make smooth production
flow, when necessary.
 Maintain the space around the fire extinguishers and evacuation passages free.

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How Much Have You Learned?

Directions: Encircle the letter of the correct answer.

1. A maintenance process of moving assembled parts and hand tools through the
use of oil and greases.
A) Simple Repair
B) Lubricating
C) Hand Sharpening
D) Tightening
2. What is considered a minor repair?
A) The task not too long to perform
B) Whole item to be replaced
C) Motor overhauling
D) Cleaning
3. Proper storage of hand tools entails:
A) Placing hand tools together in one place.
B) Labeling hand tools properly in the tool cabinet.
C) Keeping hand tools in anyplace in the tool room.
D) Lubricating tools
4. “Urgent repair” is similar to:
A) maintenance schedule
B) maintenance Inspection
C)
D) an ordinary routine
E) an immediate repair
5. Don‟t pile up jigs, tools and materials without:
A) label
B) separator
C) identification
D) stamping

Congratulations! You did a great job! Rest

and relax a while then move on to the
next lesson. Good luck!

Apply safety practices

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Definition of Terms
Bacteria – simple, one-celled organisms that may or may not be harmful..
Biological hazards- hazards caused by living organisms which include insects, molds, fungi,
viruses, and bacterial contamination.

Ergonomic hazards- hazards are commonly seen in the workplaces which are
improperly designed tools or work areas
Fuel - any substance, which will combine in the presence of heat-that is, a fuel is
“something that will burn”.

Initial triage and tagging- sorting patients into categories of priority for care and transport based on
the severity of injuries and medical emergency.

Leather jacket-is made of chrome leather and prevents the entry of sparks between the clothes
and body.

Mandatory signs- regulatory signs which indicate that an instruction must be carried out.
Materials handling- a technique which include the art of lifting, placing, storing or movement
of materials through the use of appropriate handling equipment and men. Physical Hazards-
hazard due to the transfer of energy between an object and a worker.

Prohibition signs- are regulatory signs which indicate that an action activity is not allowed.
Protective sleeves are made from leather to protect the arms.
Regulatory Signs- signs contain instructions that need to be complied with them constitutes an
offense under law, standing orders, company policy.

Safety Shoes- safety shoes have heat-resistant soles and impact-resistant toes. Warning Signs-
signs which warn of hazard or hazardous condition that is likely to be life-threatening.

Welding gloves/gauntlet- made of chrome leather and protects the hands from heat, spatter, and
radiations.
Welding shield/helmet- used to protect our face and eyes from the arc rays and heat, and the
spatter from the molten metal.
Welding spats- made of chrome leather and protects the feet from spatter

Acronyms
OSHS- Occupational Safety and Health Standards PPE- Personal Protective Equipment

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LEARNING OUTCOME

PERFORMANCE STANDARDS
 Hazards are identified correctly in accordance with OHS (occupational health
and safety) procedures.
 Safety signs and symbols are identified and adhered to in accordance with
workplace safety procedure.

Identify hazardous area

Environmental Hazards
1. Physical Hazards. Hazards due to the transfer of energy between an object and a worker.
 Excessive noise
 Inadequate illumination
 Extreme temperature
 Extreme pressure
 Vibration
 Radiation
 Inadequate ventilation
 Cluttered area
 Ignorance or carelessness of the worker

2. Chemical Hazards. These hazards arise from inhaling chemical agents in the form
of vapor gases, dust, fumes, mist, or by skin contact with these materials.
 Mist Fine particles of a liquid float in air
 Gases- substances in gaseous state but are always airborne at room
temperature.
 Vapor- results when substances that are liquid at room temperature evaporate.
 Dust- solid harmful substances are ground, cut or crushed by mechanical
actions.
 Fumes- gas is condensed in air, chemically changed and becomes fine solid
particles which float in air.
Four Possible Routes of Entry of Chemical Hazards

1. Inhalation- breathing in toxics is the most common and dangerous route.

2. Ingestion- toxics enter through the gastrointestinal tract.
3. Absorption- toxics pass through skin into the bloodstream.
4. Injection- toxics may be injected into the body (needles, ect.)- the least
common, yet most direct route of entry

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3. Biological Hazards. Hazards caused by living organisms which include insects,
molds, fungi, viruses, and bacterial contamination; from defects in sanitation and
housekeeping procedures, such as in the provision of potable water, removal of
industrial wastes and sewage, food handling , and personal cleanliness.

Agents of Biological Hazards

 Bacteria – simple, one-celled organisms that may or may not be harmful.
 Viruses – organisms that depend on a host cell for development or
reproduction
 Fungi – may be small or large parasitic organisms growing in a living or
dead plant or animal
 Rickettsia – rod-shaped microorganisms that are smaller than bacteria and
depend on a host for development or reproduction. Microorganisms
transmitted by fleas, ticks, and lice

Common Health Problems from Biological Hazards

a. Tuberculosis (TB)
b. Tetanus
c. Viral Hepatitis
d. HIV/AIDS

Diseases caused by virus

a. Upper Respiratory Tract Infection
b. Hepatitis B Infection
c. Acquired Immunodeficiency Syndrome (AIDS)
d. Rabies

4. Ergonomic Hazards. Hazards commonly seen in the workplace, which are

improperly designed tools or work areas, improper lifting or reaching, poor visual
conditions or repeated motions in an awkward position that may be responsible for
fatigue, stress and strain and may lead to accidents in the occupational environment.

Ergonomics is si the study of designing equipment and devices that fit the workers
Effects of Ergonomic Hazards
a. low productivity
b. high rate of errors
c. material wastage and equipment
Health Problems caused by Ergonomics
a. musculoskeletal problems
b. vascular problems
c. visual problems
d. hearing problems
e. skin problem
f. psychological problems

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 Personal Protective Equipment (PPE)

 Helmet type welding shield is more convenient to use because

it allows both hands to work freely

 Hand-held shield allows only one hand to work

freely.

 Leather jacket is made of chrome leather and prevents the entry of

sparks between our clothes and body.

 Welding gloves/gauntlet is made of chrome leather

and protects our hands from heat, spatter, and radiations.

 Face shield is best for general protection because it can be worn

under an arc welding helmet

 Leggings are made from leather to protect the legs and

feet.

 Protective sleeves are made from leather to protect

the arms.

 Protective cover all are made from light asbestos coated with aluminum
to protect the whole body during welding

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 Welding cushions are made from leather for

sitting and kneeling beside the work piece as
protection against cold

 Safety Shoes- have heat resistant soles and impact

resistant toes. Some safety shoes have metal in
soles, while others protect workers from different
types of electrical hazards.

 Safety goggles- are used when grinding and

chipping off slag

 Earplugs- is a pair of device that is meant to be

inserted in the ear canal to protect the wearer's
ears from loud noise or intrusion
 Respirators- is an apparatus worn over
the mouth and nose or the entire face to
prevent the inhalation of dust, smoke, or
other noxious substances.

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Protection Clothing against sparks and

hot metals

SHIELDED
K to 12 –

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Welding Safety

1. Electric shock – maybe caused by open and not properly insulated cable, workers
are advised to regularly check electrical wiring connection.

Check primary circuit wiring connection

Check welding cable for crack or cut insulation

Do not put welding cable around the part of your body.

2. Arc rays can damage both eyes and skin, so wear proper protective clothing and
filter lenses.

BURN CAUSED BY LIGHT

 Ultra violet light- can cause first degree or second degree burn to the eyes and skin
 Infrared – wave that is felt as heat
 Visible light- light that we see producer of varying quantities and color

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3. Fumes and Gases- Use proper ventilation and position yourself out of the fume flow.

The bigger diameter of the electrode, the more ventilation is required.

Dangerous powder dust comes from weld fumes filtered during welding
4. Fire and explosion- may result from faulty welding operation .Always understand the
environment where your are welding and never take anything for granted.

5. Compressed gas- must be handled in such a way as to prevent personal or equipment

damage.

6. Face and eye protection - must be worn at all times in the workplace. This includes
safety goggles and full -faced mask.

7. Wear correct eye, ear, and body protection.

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How Much Have You Learned?

Direction: Read and analyze the statement carefully. Encircle the best answer
1. Which hazards are due to transfer of energy between an object and a worker?
A. Chemical hazards C. Physical hazards
B. Biological hazards D. Ergonomics hazards
2. Which kind of hazard causes deadening of a welder‟s hand because of
unadvisable position during welding?
A. Chemical hazards C. Physical hazards
B. Biological hazards D. Ergonomics hazards
3. Impact resulting from being struck by and struck against objects may cause
serious accidents which one is referred to?
A. Chemical hazards C. Physical hazards
B. Biological hazards D. Ergonomics hazards
4. Which process do toxics pass through gastrointestinal organ?
A. Ingestion C. Inhalation
B. Absorption D. Injection
5. People who work with animals, animal products or animal wastes have a
greater risk of infection because of .
A. Chemical hazards C. Physical hazards
B. Biological hazards D. Ergonomics hazards

Directions: Identify the term that is described: Column A and choose the correct
answer to Column B. Write your answer before each number

A. Welding shields/helmet
_____1. The most common and painful injuries that occur in B.Occupational
the welding shop. safety health
_____2. An immediate care given to a person who has been standard
injured or suddenly taken illness
_____3.A symbol used to indicate a potentially hazardous C.Burn
situation which, if not avoided , could result in death or serious injury. D. First aid
_____4.Mandatory rules and standards set and enforced to E. Caution
eliminate or reduce hazards in the workplace. F. Hazard
_____5.It is used to protect our face and eyes from the arc rays
and heat and the spatter from the molten metal.

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Safety Signs and Symbols
Introduction
Safety symbols are pictures sometimes called safety pictographs,
pictograms, or pictorials. They are used in place of, or as a supplement to
written words. These symbols provide warnings or alerts about a possible
hazard.
Because pictures may convey information better than words, graphic
symbols are added to precautionary labels to show major workplace dangers
like welding or cutting hazards.
The use of symbols on precautionary labels is optional, and is
recommended for the following reasons:
 Symbols may show and help to explain the hazards quickly.
 Symbols can be understood by both readers and non-readers.
 Symbols may be multilingual and usually translate directly into
all languages.
Welding and cutting industry has adopted standardized symbols and
uniform methods of use to avoid user confusion and to supplement and
reinforce the written message.

Words

The large word at the top of the label is called the signal word. It is used
in combination with a specific colored background and combined with the
safety alert symbol to indicate the degree of seriousness of a potential hazard.
Because of its colored background, the signal word is usually the first element
that you notice when looking at a safety label. According to International
Standard Organization (ISO), there are three (3) choices for a signal word:
1. DANGER. Used to indicate
an imminently hazardous
situation which, if avoided, will
result in death or serious injury.
The use of this signal word should
be limited to the most extreme
situations.

3. WARNING. This indicates a

potentially hazardous situation which,
if not avoided, could result in death or
serious injury.

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4. CAUTION. Used to indicate a potentially
hazardous situation which, if not avoided, may
result in minor or moderate injury. CAUTION may
also be used without the safety color symbol (the
triangle with exclamation mark) to indicate
property-damage-only.

Classification of Safety Signs

1. Regulatory Signs- signs contain instructions. Failure to comply with them

constitutes an offense under law, standing orders, company policy, etc.

a. Mandatory signs are regulatory signs which indicate that an instruction must be
carried out. When symbols are used they are white on a blue disc. Text-only
mandatory signs are black on white in a portrait format

1. Prohibition signs are regulatory signs which indicate that an action or activity is
not allowed. The symbolic shape used on prohibition signs is the red circle and slash
over a black symbol. Prohibition signs may contain only the red circle and text with
no symbol.

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2. Warning Signs- signs which warn of a hazard or hazardous condition that is
not likely to be life-threatening. The symbolic shape used on warning signs is
black triangle with yellow interior and black symbol. The word warning is not
required to print on the sign, although it is often used for added impact.

1. Danger Signs- signs which warn of a hazard or

hazardous condition is likely life- threatening. It is
recommended that symbols not be used on danger
signs.

2. Fire Signs- advice the location of

fire alarms and firefighting
equipment. Fire signs contain a white
symbol and/or text on a red
background.

3. Emergency Information Signs- indicate the

location of, or direction to, emergency-
related facilities (exits, first aid, safety
equipment, etc.). These signs feature a white
symbol and/or text on a green background.

4. General Information Signs- communicate

information of a general nature in order to avoid
misunderstanding or confusion. These signs often
refer to housekeeping, company practices and
logistics.

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How Much Have You Learned?

Direction; Read and analyze each statement carefully. Choose the best answer and write the
letter only on your answer sheet.

1. Pictures that are used to inform workers on safety practices are .

A. Cautions
B. Warnings
A. Prohibitions
B. Safety signs

2. Signs which indicate that an action is not allowed are .

A. regulatory signs
B. mandatory signs
C. prohibition signs
D. warning signs

3. Which are used to indicate a potentially hazardous situation which, if not avoided,
may result in minor or moderate injury?
A. Danger
B. Caution
C. Warning
D. Emergency

4. Signs indicate that an instruction must be carried out .

A. regulatory signs
B. mandatory signs
C. prohibition signs
D. warning signs

5. Which used to indicate an imminently hazardous situation which, if avoided, may

result in death or serious injury?
A. Danger
B. Warning
C. Caution
D. Emergency

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Occupational Safety and Health Standards
Introduction

Occupational Safety and Health Standards (OSHS) are mandatory rules and
standards set and enforced to eliminate or reduce occupational safety and health hazards
in the workplace
OSH Standards aim to provide at least the minimum acceptable degree of protection that
must be granted to every worker in relation to dangers of injury, sickness, or death that may
arise by reason of his or her occupation. The provision of OSHS by the government is an
exercise of police power, with the intention of promoting the welfare and well-being of
workers.

Coverage and Scope of OSHS

All establishments, workplaces, and undertakings are covered, including agricultural

enterprises whether operating for profit or not, except:
1. Residential places exclusively devoted to dwelling purposes.
2. Those directly engaged in land, sea and air transportation (however, their
dry dockets, garages, hangers and maintenance, and repair shops and offices
are covered.
3. The activities of a lessee regarding the safety of a mining claim or lease,
including mines safety, mineral conservation, and pollution in
establishments or work places falling under the mining industry.
Minimum Standards on Safety and Health in the Workplace

The OSHS require every company to keep and maintain its workplace free from
work hazards that are likely to cause physical harm to the workers or damage to
property.
The following must be provided by the employer;
 Appropriate seats, lighting, and ventilation.
 Adequate passageways, exits, and firefighting equipment
 Separate toilet facilities and lockers for men and women.
 Appropriate safety clothing like protective gear, masks, helmets, safety
boots, coats, or goggles.
 Medicines, medical supplies, or first-aid kits.
 Free medical and dental services and facilities.
Safety Measures to be Observed within the Premises of Establishments

 Building premises shall have adequate fire, emergency or danger signs

and safety instructions of standard colors and sizes visible at all times.
OSH Standards aim to provide at least the minimum acceptable degree of protection that
must be granted to every worker in relation to dangers of injury, sickness, or death that may
arise by reason of his or her occupation. The provision of OSHS by the government is an

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exercise of police power, with the intention of promoting the welfare and well-being of
workers.

Coverage and Scope of OSHS

All establishments, workplaces, and undertakings are covered, including agricultural
enterprises whether operating for profit or not, except:
 Residential places exclusively devoted to dwelling purposes.
 Those directly engaged in land, sea and air transportation (however, their dry dockets,
garages, hangers and maintenance, and repair shops and offices are covered.
 The activities of a lessee regarding the safety of a mining claim or lease, including mines
safety, mineral conservation, and pollution in establishments or work places falling
under the mining industry.

Minimum Standards on Safety and Health in the Workplace

The OSHS require every company to keep and maintain its workplace free from
work hazards that are likely to cause physical harm to the workers or damage to
property.
The following must be provided by the employer;
 Appropriate seats, lighting, and ventilation.
 Adequate passageways, exits, and firefighting equipment
 Separate toilet facilities and lockers for men and women.
 Appropriate safety clothing like protective gear, masks, helmets, safety
boots, coats, or goggles.
 Medicines, medical supplies, or first-aid kits.
 Free medical and dental services and facilities.
Safety Measures to be Observed within the Premises of Establishments

 Building premises shall have adequate fire, emergency or danger signs

and safety instructions of standard colors and sizes visible at all times.
Responsibilities of Employers and Employees under OSHS

Duties of Employers
 Adopt administrative policies on safety in accordance with the provisions
of the standards.
 Report to the Regional Director or his/her duly authorized representative
the policies adopted and the safety organization established.
 Submit to the Regional Director or his/her duly authorized representative
once every three months a report on the safety performance, safety
committee meetings and its recommendations and measures taken to
implement the recommendation.
 Act on recommended safety measures and provide access to appropriate
authorities.

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Duties of Employees
 Follow safety policies.
 Report unsafe conditions and practices to the supervisor.
 Serve as member of the Health and Safety Committee, when called upon to do so.
 Cooperate with the Health and Safety Committee.
 Assist government agencies in the conduct of safety and health inspection.

Rule 1100: Gas and Electric Arc Welding and Cutting Operations 1100.01:

General Provisions:

1. Welding or cutting operations shall not be permitted in rooms or areas containing combustible
materials or in proximity to explosives or flammable liquids, dusts, gases, or vapors, until all
fire and explosion hazards are eliminated.
2. Welding or cutting operations on containers filled with explosives or flammable substance is
prohibited. Welding closed containers that have held explosive or flammable substance shall
only be undertaken after the containers have been thoroughly cleaned and found completely free
of combustible gases or vapors of the containers are filled with inert gas or with water.
3. Welding and cutting operations carried out or done in places where persons other than the
welders work or pass shall be enclosed by means of suitable stationary or portable screens.
Screens shall be opaque, of sturdy construction to withstand rough usage of a material which
will not readily be set on fire by sparks or hot metal at least 2 meters (6.5 feet) high, and
preferably painted with light flat paint.
4. A portable fire extinguisher shall be provided at the place where welding and cutting operations
are being undertaken.
5. Before welding and cutting operations are allowed in large establishments, the area shall be
inspected by the safety man. He shall issue a written permit or authorization for welding and
cutting, indicating there in the precautions to be followed to avoid fire or accidents.
1100.02: Personal Protective Equipment:
1. All workers or persons directly engaged in welding or cutting operations shall be provided
with the following personal protective equipment:
a. goggles, helmet, or head shields fitted with suitable filter lenses and hand shields, and
b. suitable aprons

2. All personnel directly assisting in welding or cutting operations shall be provided with
goggles or other protective clothing, as may be necessary.
1100.03: Welding or Cutting in Confined Spaces:
Inherit of any fumes, gases, or dusts by persons welding or cutting in confined spaces
shall be prevented by the provision of:
1. Local exhaust and general ventilation system to keep fumes, gases, or dusts within
allowable concentrations or threshold limit values.
2. Approved types of respiratory protective equipment

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How Much Have You Learned?

Directions: Read and analyze each statement carefully. Choose the best answer.

1. Safety standards are mandatory rules set and enforced to eliminate or reduce,
A. welding defects
B. welding injuries
C. welding problems
D. hazards in the workplace

2. The governments purpose of creating Occupational Safety and Health Standards is to

.
A. produce quality output
B. produce safety personnel
C. promote welfare and well-being of workers
D. protect the rights of the workers against abusive employers

3. Under Rule 1100.01 of the gas and electric arc welding operations, welders
are .
A. provided with PPE by employers
B. provided with exhaust and ventilated system
C. protected from any violations against their rights
D. prohibited from working in areas prone to combustible materials

4. Rule 1100.02 states that workers must be

A. provided with PPE by employers
B. provided with exhaust and ventilated system
C. protected from any violations against their rights
D. prohibited from working in areas prone to combustible materials

5. Concerning welding or cutting in confined spaces under Rule 1100.03, welders are
A. provided with PPE by employers
B. provided with exhaust and ventilated system
C. protected from any violations against their rights
D. prohibited from working in areas prone to combustible materials

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How Much Have You Learned?

Directions: Make your own Mechanical Workshop Floor Plan Layout and indicate the
list of tool and equipment?

How Much Have You Learned?

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Direction: Make a tool box using illustration board and read the following
instruction below how to build a toolbox metal sheet.
Lesson Information
a. Lesson Title: Building a Sheet Metal Toolbox (also counts for Metal Shop orientation)
b. Lesson Length: 4 hours
c. Number of participants: 4
II. Learning Outcomes: Objectives
a. Audience
● Anyone interested in learning basics of sheet metal forming
● No previous knowledge necessary
b. Objectives
● Sheet metal pattern making
● Sheet metal cutting
● Sheet metal bending
● Riveting
III. Content Outline, Questions, and Key Terms (Lesson Content/Skills)
a. Content Outline and Background Information)
1.Sheet metal pattern making
a) Like a cube made out of origami
b) Folds take up space, based on thickness of sheet metal
c) Helpful to practice with cardboard or paper first
i) Plan out order of bends so don’t run into each other
d) Straight lines and right angles are key for boxes
e) Use scribes as a best practice instead of a pen/marker to mark on sheet metal
(sharpie fine this time)
2) Sheet metal cutting
a) Shear
i) Long flat cuts
b) Band saw
i) For smaller, detailed, and/or inside cuts
3) Sheet metal bending
a) Brake
i) Used to fold sheet metal
ii) Clamping pressure enough to hold sheet metal in place but not forced down
iii) Clamp should be back at least 1.5 times the material thickness from the apron
(bending part) as to not damage the clamp. Beyond that, it’ll lead to bigger
bending radii.
b) Hemming
i) Get rid of rough, sharp edge on sheet metal
ii) Like sewing
iii) Fold as much as possible on the brake, flip upside down and press down to
close the gap to 180 degrees
(1) Don’t put undue pressure on the brake, can also use a hammer for the second ste

4) Riveting
a) Drill press based on hole size
b) Pop rivet gun used to insert rivets
c) Have to drill out to remove them

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b. Major Messages, Big Concepts
● Always square edges
● Measure twice, cut once
● Sheet metal has thickness, bends have radii

c. New and Key Terms

● Brake - metalworking machine used to bend sheet metal
● Hemming - when the sheet metal is folded back on itself
● Shear - metalworking machine used to cut sheet metal
● Rivet - permanent mechanical fastener

d. Possible misconceptions (m) and prior knowledge/skills (pk)

● Sheet metal cutting (pk)
● Sheet metal bending (pk)
● Drilling (pk)
● Riveting (pk)
● Right angles and boxes are easy to make (m)

IV. Lesson Delivery Procedure(s) and Strategies

Time Procedure - hands-on demonstration, example

a. Set-Induction and Lesson Opening
1) Basic, getting attention since already know what class they signed up for
a) Focus/Attention Getter: Introduce self, go around saying name, why signed up for class,
what do during the day
b) Interest Builder: “Sheet metal seems like it should be simple to work with, but in order to
end up with an object you’re proud of, there are some specific ways of forming it that you’ll
want to know.”
2min c) Relevance: “You’ll learn skills that’ll be applicable and helpful for any future sheet metal
projects that you’ll want to do.”
d) Student Objective: “By the end of today’s class, you should be walking out of here with a
usable toolbox
b. Body of the lesson
15mins 1) Metal shop orientation/safety
2) Walk through the process of making the toolbox
3) Sheet metal pattern making
5mins a) Have example paper patterns for the toolbox and handle, show and explain it
b) Use pattern and t-square and demonstrate how scribe works on sheet metal
i) Easier to use sharpie (width of band saw blade) in this instance
c) Tape pattern to sheet metal, then go around with sharpie
i) Mark main toolbox pattern on both sides of sheet metal
d) Any questions?
4) Sheet metal cutting
a) Shear
i) Demonstrate how to do a long cut on the shear, lining it up squarely
5mins b) Band saw
i) Adjust band saw height to just above sheet metal
ii) Demonstrate how to cut a triangle out of the material
c) Snips
i) used for getting in to hard to reach spots from band saw
d) Any questions?
5) Sheet metal bending

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a) Brake
i) Show accurate clamping pressure
10mins ii) Demonstrate a 90 degree bend
b) Hemming
i) Demonstrate a hem on the brake
ii) Demonstrate a hem with hammer
c) Show how to bend with clamp if can’t get specific spacing or direction needed on the
brake
d) Pay attention to bend numbers on templates
e) Any questions?
6) Riveting - can show later, after they get closer to finishing the box
a) Show set up for drilling holes once toolbox is folded
10mins i) Clamps to keep bent in parts from bending away
ii) Punch center before drilling so drill bit goes in where intended
b) Demonstrate how a pop rivet gun is used
c) Any questions?
7) Finishing
a) File down or grind away any sharp edges
1min i) Make sure wheel turns in direction of the fold, not away from it (will bend it back)
b) Sanding, bead blasting
c) Any questions?
c. Conclusion
1min 1) Show example finished toolbox, just one possibility of many
a) “And now it’s time for you to actually build your own toolbox!”
d. Extended Activity/Practice
1) Building their own toolboxes
3-4hrs a) Wander around
b) Make sure things are going smoothly, no one’s going to hurt themselves or majorly mess
up their toolbox, etc.
c) Answer questions
d) People can leave when they’re done making their toolbox
2) If share emails, can send resource links, Fusion360 info, etc.
a) Fusion360 sheet metal abilities:

V. Assessment and Evaluation

List the ways you can assess whether your students are working towards the learning objectives.
● Able to produce a feasible pattern
● Able to cut the sheet metal for the pattern properly
● Able to bend the sheet metal following the pattern
● Able to drill holes and rivet the toolbox together
● Ultimately, a finished, usable toolbox

VI. Diversity and Enhancements

List any items that you will include in this lesson to increase the content for diverse learners.
● Specific design features they’d want for their toolbox
o Different end designs
o Dividers inside the box
o Punching words into the side before bending

VII. Classroom Management and Logistics

List any classroom management and/or logistic items

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● Band saw
● Shear
● Brake
● Safety equipment (safety glasses, earplugs)

VIII. Safety/Equipment Reviews and Considerations

List any safety items you need to review with your students (or equipment care)
● Long hair tied back
● No jewelry, watches, etc.
● Safety glasses at all times
● Earplugs when using the band saw
● Gloves are optional when handling sharp-edged sheet metal

IX. Resources: Instructional/Content Aids, Materials, Small Equipment

Instructional Aids Materials (per student) Small Equipment (per student)
Example pattern Illustration board or Pencil & sharpie
Example toolbox Cardboard/paper Ruler
Used galvanized steel: Scissors
Sheet metal 24” x 12” 20 gage Paperclips
(~0.0375” thick) Can share:
Sheet metal 14” x 4” 20 gage Snips
Rivets 14 ⅛ Hammer
Center punch
Pop riveter
⅛” drill bit
Drill
Tape

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LATHE
Introduction

A lathe is a machine tool which spins a block of material to perform various operations such
as cutting, sanding, knurling, drilling, etc. or deformation with tools that comes in contact with the
work piece to create an object which has symmetry about an axis of rotation. Lathes are used in
woodturning, metalworking, metal spinning, and in glass working. Lathes can be used to shape
pottery as well. Most suitably metalworking lathes can be used to produce most solids of revolution,
plane surfaces and screw threads or helices. The material can be held in place by either one or two
centers, at least one of which can be moved horizontally to accommodate varying material lengths.
Ornamental lathes can produce three-dimensional solids of incredible complexity. Machine shop
personnel must be thoroughly familiar with the lathe and its operations to perform various tasks.

Principal of Operations

The lathe is a machine tool used principally for shaping articles of metal (and sometimes
wood or other materials) by causing the work piece to be held and rotated by the lathe while a tool
bit is advanced into the work causing the cutting action. The basic lathe that was designed to cut
cylindrical metal stock has been developed further to produce screw threads, tapered work, drilled
holes, knurled surfaces, etc. The typical lathe provides a variety of rotating speeds and a means to
manually and automatically move the cutting tool into the work piece

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Lathe and its Parts Headstock Contains the spindle in two preloaded ball bearings
Spindle The spindle is inside the headstock and is driven with a belt running from
the motor pulley to a pulley on the rear end of the spindle shaft. The nose
of the spindle is treaded on the outside to receive chucks and tapered on
the inside to receive other accessories.
Chucks A 3-jaw or 4-jaw chuck threads onto the spindle nose to hold your work, a
drill chuck are used on the tailstock to center drill your part.
Tool Post Attaches to the lathe table and holds a 1/4" square cutting tool
Cross Slide Table Also sometimes spelled "cross slide," it is the table with two T-slots that
holds the tool post.
Cross Slide A tapered plastic wedge that is held in place by a gib lock. It fits between
Gib the angled surfaces of the dovetail and is used to adjust for wear. As wear
occurs and the table develops "slop," the lock is loosened and the gib is
pushed further into the gap, taking up any play. This allows the machine
to always be kept in peak adjustment.
Tail Stock spindle Has a #0 Morse internal taper for holding chucks and other tools. A hand
wheel moves it in and out for drilling
Tail Stock Locking Screw Locks the tailstock in place on the bed to keep it from moving.
When loosened, the tailstock can be slid up and down the bed.
Bed The dovetailed steel bar that the saddle and tailstock are moved back and
forth on.
Saddle The part that supports the cross slide table and is moved up and down the
bed using the lead screw hand wheel.
Saddle Gib Functions like the cross slide gib to keep the saddle in tight adjustment
against the dovetailed bed.
Lead Screw The threaded screw under the bed that controls movement of the saddle.
A "saddle nut" underneath attaches the bed to the leadscrew. Turning the
lead screw hand wheel moves the saddle down the bed.
Tail Stock Gib A brass part attached to the base of the tailstock that runs on one of the
bed dovetails. The brass part is expected to wear rather than the more
expensive bed and can be adjusted for tightness as it wears.
Lathe Base The cast metal base upon which the lathe bed and headstock sit.
Drawbolt Goes through the hole in the spindle to draw chucks and other accessories
into the headstock taper inside the spindle. A special washer locates it on
center in the spindle hole.
Morse Arbor The tailstock drill chuck normally has a #0 Morse arbor threaded into the
back of it for use in the tailstock spindle. That arbor can be removed and
replaced with the #1 Morse arbor so the drill chuck can be used in the
headstock.
Dead Centers #1 and #0 Morse arbors have a 60° point and are used to locate and hold
work "between centers" on the lathe. The #1 Morse arbor rotates with the
headstock, but because the tailstock spindle does not rotate, the rear #0
Morse arbor is called a "dead" center. This needs to be kept lubricated
because it creates friction with the moving part it is locating. Most
machinists eventually replace this with a "live" center that turns on a ball
bearing.
Tommy Bars Round steel bars used to tighten and loosen chucks and other spindle
accessories. Sometimes called "Spindle Bars."
Faceplate A cast plate that threads onto the spindle nose. A work piece can be
bolted to it as an alternative to using a chuck. It has three slots to drive a
drive dog.
Drive Dog Also called a "Lathe Dog," this part is attached to a piece of bar stock by
means of a screw that goes through the side and the long point is placed
into one of the slots in the faceplate. The part is located between the lathe
centers (live or dead) and when the faceplate turns, the dog actually drives

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the piece to rotate it for cutting. It also acts as a universal joint when
turning a part between centers when the headstock is rotated to a slight
angle, allowing a tapered part to be cut.

Head Stock Locking Screw Holds the headstock in place. The screw is a pointed set screw. The point
engages a tapered groove in the pin that sticks up out of the lathe bed.
When the screw is tightened, it pulls the headstock down onto the
alignment key and holds it tight against the lathe bed.
Alignment Key A precision ground key that fits in slots in the top of the bed and bottom
of the headstock to keep the headstock aligned straight with the tailstock.
Removing this key and rotating the headstock allows tapers to be cut.
V-belt A Kevlar-reinforced Urethane belt that drives the spindle by means of the
pulleys.
2-Position Pulley The motor turns a maximum of about 6000 RPM. Putting the drive belt in
the normal (rear) position gears the motor down about 2:1 for a maximum
speed of about 2800 RPM. The "High Torque" position (closest to the
headstock) gears it about 4:1 for lower speed but more torque when
needed for heavy cuts.
Variable Speed Control Controls motor speed from 0 to 2800 RPM
Knob

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MILLING MACHINE
Introduction:
Milling machine is one of the most versatile conventional machine tools with a wide
range of metal cutting capability. Many complicated operations such as indexing, gang milling,
and straddle milling etc. can be carried out on a milling machine. Milling machines are among
the most versatile and useful machine tools due to their capabilities to perform a variety of
operations.

They can be broadly classified into the following types:

Column and Knee type milling machines:

Used for general purpose milling operations, column and knee type milling machines are the
most common milling machines. The spindle to which the milling cutter is may be

 Horizontal Milling Machine

 Vertical Milling Machine.
 Universal milling Machine
 Bed type Milling Machines:
In bed type machines, the work table is mounted directly on the bed, which replaces the
knee, and can move only longitudinally. These machines have high stiffness and are used for
high production work.

Planer Milling Machines:

Planer machines are similar to bed type machines but are equipped with several cutters
and heads to mill various surfaces.

Rotary Table Milling Machines:

Rotary table machines are similar to vertical milling machines and are equipped with
one or more heads to do face milling operations.

Tracer Controlled Milling Machines:

Tracer controlled machines reproduce parts from a master model. They are used in the
automotive and aerospace industries for machining complex parts and dies.

Computer Numerical Control (CNC) Milling Machines:

Various milling machine components are being replaced rapidly with computer numerical
control (CNC) machines. These machine tools are versatile and are capable of milling, drilling,
boring and tapping with repetitive accuracy.
Special Purpose Milling Machine:
Example: A five-axis profile milling machine having three principal linear movement
and two angular movements of machine components

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Parts
Column:
The column houses the spindle, the bearings, the gearbox, the clutches, the shafts, the
pumps, and the shifting mechanisms for transmitting power from the electric motor to the
spindle at a selected speed.
Knee:
The knee mounted in front of the column is for supporting the table and to provide an
up or down motion along the Z axis.
Saddle:
The saddle consists of two slide ways, one on the top and one at the bottom located at
90º to each other, for providing motions in the X or Y axes by means of lead screws.
Table:
The table is mounted on top of the saddle and can be moved along the X axis. On top of
the table are some T-slots for the mounting of workpiece or clamping fixtures.
Arbor:
The arbor is an extension of the spindle for mounting cutters. Usually, the thread end of
an arbor is of left hand helix.

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Parts
Column:
The column houses the spindle, the bearings, the gearbox, the clutches, the shafts, the
pumps, and the shifting mechanisms for transmitting power from the electric motor to the
spindle at a selected speed.

Knee:
The knee mounted in front of the column is for supporting the table and to provide an
up or down motion along the Z axis.

Saddle:
The saddle consists of two slide ways, one on the top and one at the bottom located at
90º to each other, for providing motions in the X or Y axes by means of lead screws.

Table:
he table is mounted on top of the saddle and can be moved along the X axis. On top of
the table are some T-slots for the mounting of workpiece or clamping fixtures.

Milling head:
The milling head consisting the spindle, the motor, and the feed control unit is mounted
on a swivel base such that it can be set at any angle to the table.

Ram:
The ram on which the milling head is attached can be positioned forward and backward
along the slide ways on the top of the column.

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SHAPING MACHINE
Introduction:
A shaper is a type of machine tool that uses linear relative motion between the work piece
and a single-point cutting tool to machine a linear tool path. The shaper is a relatively simple
machine. It is used fairly often in the tool room or for machining one or two pieces for prototype
work. Tooling is simple, and shapers do not always require operator attention while cutting. A
shaping machine is used to machine flat surface. It can cut grooves, angles and many other
shapes. The Main Function of shaper is to generate a flat surface by combination of linear
movement of cutting tool and work piece.
Shaping is where the work piece is fed at right angles to the cutting motion between
successive strokes of the tool. Shaping and planners among the oldest techniques used and
Shapers are where the work piece is fed at right angles to the cutting motion between successive
strokes of the tool. In Planners the work piece is reciprocated and the tool is fed at right angles
to the cutting motion. These processes require skilled operators and for the most part have been
replaced by other processes
The horizontal shaper is the most common type and its principal components are shown
below and described as follows:

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Parts of Shaper:
Base:
It is a heavy and robust cast iron body. The base supports the column or pillar which
supports all the working parts such as ram, work-table, drive mechanism etc.
Column or Pillar:
The column is a ribbed casting of cellular construction. The ram slide ways are provided
on the top of the column while the table slide ways are machined on the front. The crank and
slotted link mechanism that drives the ram is contained within the column. The
driving motor, variable speed gear box, levers, handles and other controls of shaper are also
contained in the column.
Ram:
Ram is a rigidly braced casting and is located on the top of the column. The ram slides
back and forth in dovetail or square ways to transmit power to the cutter. The starting point and
the length of the stroke can be adjusted using stroke positioning mechanism and the down feed
mechanism.
ool head:
It is the device which holds the tool. The tool head slides in a dovetail at the front of the
ram by means of T-bolt sand is fastened to the ram on a circular plate so that it can be rotated for
making angular cuts. It can swivel from 0° to 90° in a vertical plane. The tool head can be raised
or lowered by hand feed for vertical cuts on the work piece by its hand crank for precise depth
adjustments.
Clapper Box:
The clapper box is needed because the cutter drags over the work on the return stroke.
The clapper box is hinged so that the cutting too] will not dig in. Often this clapper box is
automatically raised by mechanical, air, or hydraulic action.
Cross Rail:
The Cross rail is a heavy casting attached to the column at its front on the vertical guide
ways. It carries the horizontal table slide ways. The cross rail can be raised or lowered by means
of an elevating screw in order to compensate for different thicknesses of work.
Table:
It is made of cast iron and has box type construction. It holds and supports the work during
the operation and slides along the cross rail to provide feed to the work. T-slots are provided on
its top and sides for securing the work to it. The table is moved left and right, usually by hand, to
position the work under the cutter when setting up. Then, either by hand or more often
automatically, the table is moved sideways to feed the work under the cutter at the end or
beginning of each stroke.
Saddle:
The saddle moves up and down (Y axis), usually manually, to set the rough position of
the depth of cut. Final depth can be set by the hand crank on the tool head.
Tool holders:
Tool holders are the same as the ones used on at engine lathe, though often larger in size.
The cutter is sharpened with rake and clearance angles similar to lathe tools though the angles
are smaller because the work surface is usually flat. These cutters are fastened into the tool holder.
Work holding:
Work holding is frequently done in a vise. The vise is specially designed for use in shapers
and has long ways which allow the jaws to open up to 14" or more, therefore quite large work
pieces can be held. The vise may also have a swivel base so that cuts may be made at an angle.
Work that cannot be held in the vise (due to size or shape) is clamped directly to the shaper table
in much the same way as parts are secured on milling machine tables.

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How Much Have You Learned?

Directions: Explained the following parts of lathe machine

Lathe and its Parts Headstock

Spindle
Chucks
Tool Post
Cross Slide Table
Cross Slide Gib
Tail Stock spindle
Tail Stock Locking Screw .
Bed
Saddle
Saddle Gib
Lead Screw .
Tail Stock Gib
Lathe Base .
Drawbolt
Morse Arbor
Dead Centers
Tommy Bars
Faceplate .
Drive Dog
Head Stock Locking Screw
Alignment Key
V-belt
2-Position Pulley
Variable Speed Control Knob

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Directions: Explained the following parts of milling and shaping machine

MILLING MACHINE

Column:

Knee:

Saddle:

Table:

Arbor:

SHAPING MACHINE

Base: .

Column or Pillar

Ram

Tool head

Clapper Box

Cross Rail

Table

Saddle

Tool holders

Work holding:

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ARC WELDING SAFETY
Introduction

To achieve safe working conditions in the metal fabrication and welding industry, all personnel
should be able to recognize the hazards which apply to their particular occupation. Welding operators
must also know the correct operating procedures for the equipment.
An operator can be subjected to many safety hazards associated with the industry. As with any
other industrial worker, they may be injured through incorrect lifting practices, falling or tripping, or
incorrect use of hand tools and machines. The operator will also encounter particular hazards associated
with welding.
A clean, tidy workplace, free from combustible materials, is an essential requirement for the safety
of welding personnel.

Additionally, others working in the vicinity of welding operations are at risk from hazards such as
electrocution, fumes, radiation, burns or flying slag and noise. They too must be protected if their health
and safety is not to be put at risk.

In this chapter you will look at the following

Types of hazard
 electric shock
 fumes
 radiation
 fire and explosion
 burns

Personal protective equipment (ppe

The working environment
 confined spaces/hazardous locations
 cutting or welding in or near hazardous locations
 working on tanks and containers

First aid for operator

 basic objective
 basic immediate first aid for some common operator injuries.

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Types of hazards

The major hazards associated with arc welding are:

• electric shock

Fig 1.1 – Electric shock

• fumes

Fig 1.2 – Fumes

• radiation

Fig 1.3 – Radiation

• fire and explosion

Fig 1.4. – Fire and explosion

• burns.

Fig 1.5. – Burns

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To avoid electric shock, the following practices are highly recommended.

Dry gloves in good repair should be worn when

handling equipment, particularly when changing
electrodes.

Footwear should be insulating, dry, and in

good condition.

Welding equipment should be in good

repair and fully insulated.

Work return contact points should be close to the

site of welding and be carefully selected.

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All connections should be clean and tight.

Electrical supply circuits (primary) should be kept as

short as possible and be serviced only by

electrical tradespersons

Machines should be switched OFF and unplugged

when changing leads or carrying out maintenance

Dry insulating material should be used in confined

spaces; wooden boards or rubber mats are ideal

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When working in a confined

space or in wet or moist
conditions, electrodes should
not be left in the holder and
the power should be isolated
when electrodes are being
changed.

Remember, sweating decreases

body resistance. Therefore, be

extra careful when welding under

hot conditions

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PERSONAL PROTECTIVE EQUIPMENT (PPE)
Arc welding, like most welding processes, requires operators to protect themselves from
the radiated heat and rays associated with the process.

Perhaps the most efficient way of doing this is by the wearing of protective clothing. The use of
all protective clothing is dictated by the nature of the work and the comfort of the operator.

Ideally, clothing for the operator should consist of:

• long-sleeved cotton shirt

• sleeves rolled down and buttoned

• strong trousers without cuffs

• strong leather shoes or work boots

• aprons

• gloves

• spats (leather)

• caps

• leather capes or jackets.

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PERSONAL PROTECTIVE EQUIPMENT

Fig 1.10 – Dressed for safety

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The working environment

There are work situations which present increased hazards to the health and safety
of the welding operator. These are

• confined spaces
• hazardous locations
• working on tanks and containers.

Confined spaces/hazardous locations

Working in confined spaces usually entails difficult access and cramped conditions. The
workplace is often poorly ventilated, and the welder is often completely surrounded by a conductor
which forms part of the welding circuit. Under these circumstances the welding operator is at increased
risk from:

• a build-up of fumes
• electric shock.
The possibility of a build-up of dangerous fumes whilst welding in a confined space must be
allowed for and adequate ventilation be provided through:
• exhaust fans
• an additional supplementary air supply.
The possibility of an electric shock is greater because the operator can easily
make contact with the job, and awkward and enclosed workplaces often lead to higher levels of
perspiration.
The operator should keep themselves as dry as possible and use the necessary protective
clothing to prevent electrocution. Additionally:

• an all-insulated electrode holder should be used

• high-frequency attachments should not be used

• portable electric lamps exceeding 32 V supply should not be used. Electronic

leakage breakers (ELB) devices are acceptable.
Provision must be made, close to the work area, for the power to be switched off
by an assistant when:

• the welder is not prepared for welding

• the electrode is being changed
• the operator leaves the job

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Confined space regulations

The following regulations are specified as mandatory when working in a confined space.

• Adequate ventilation must be provided.

• A semi-skilled operator who is trained in rescue and resuscitation must be stationed at the manhole to
monitor the work space at all times; to adjust oxy-acetylene gear and the welding machine, whilst
continually observing the operator.
• All leads and hoses are to be kept clear of the floor, dampness and falling metal sparks. Circular vessels
must be prevented from rolling.

• General tidiness and care is essential, equipment should not be allowed to contact hot work or sharp
objects.

• Oxy-flame cutting equipment should not be left inside the confined space when not in use, and it should
always be lit by the assistant outside and then passed to the operator inside.

• Oxygen should never be used for dusting down or any purpose other than for the
oxy-flame.

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Cutting or welding in or near hazardous locations

If at all possible, work should be removed from the hazardous locations and carried out to a
safe location.

Cutting or welding in or adjacent to hazardous locations should not take place until the
following conditions have been established.

• A hot work permit has been obtained.

• Authorization has been obtained from the responsible officer.

• It is impractical to move the work to a safe area.

• The production of any hazardous or explosive substance has ceased or been excluded
from the work area.

• The location has been tested and found to be free from flammable substances.

In general terms the operator’s responsibility with respect to hazardous locations can be
expressed as follows.

• Always examine work areas for possible hazards.

• Seek authorization before proceeding with cutting or welding whenever any doubt exists.

• Work must be carried out in accordance with the provisions of the hot work permit.

• Always examine the possibility of removing the work to a safe area.

• Be vigilant in the provision and maintenance of any safety screens, doors or barriers required
to ensure safety.

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First aid for operators
Basic objectives
In the event that a person is injured or suddenly becomes ill, efficient first aid should be carried
out as quickly as possible, preferably by trained first aiders. Taken before medical help is available and
often at a critical stage, this action can save lives, reduce the severity or worsening of the injury and limit
discomfort.
Essential emergency action

This involves:
• ensuring that there is no danger to the patient or rescuer
• getting the casualty out of any danger zone, without endangering anyone
• giving first aid to the casualty.
For all but minor injury, arrange for medical assistance. If there is little risk in moving the casualty,
arrange for transport and for care during transport to a doctor, hospital or nurse. If there is any risk of
further injury posed by moving the patient, he/she should not be moved, and qualified medical help should
be sought
Basic immediate first aid for some common operator injuries
Welding flash (arc eye)

This is an eye injury caused by exposure to ultraviolet rays.

• In mild cases, add eye-drops and shade the eyes.
• In severe cases, loosely pad both eyes (cold may help) and get the casualty quickly to a doctor.

Hot particles in the eyes

• Cover BOTH eyes of the victim and take the patient as quickly as possible to a doctor.
• In the case of chemical burns (eg from acids, alkalis or similar liquids) remove the chemicals from
the eyes by washing at once with large amounts of running water and flush continuously for up to 20
minutes.
• Urgently seek medical advice.

Burns (to hand/s and body)

Minor burns
Minor burns should be immediately cooled under cold running water, then covered with steriledressing
material. Avoid the use of ointment or powder as these may interfere with any subsequent medical
treatment.

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Major burns

Since urgent action is essential, cool the area with running water quickly and over a long period to
remove any residual heat, and get the casualty to hospital as quickly as possible. Keep the casualty
covered with a light blanket or other suitable material. Care must be taken to ensure that dressings,
blankets, etc will not stick to the wound.
Electric shocks

Electric shock usually does not kill at once, but may stun the victim and stop his or her breathing.
Delay in rescue and resuscitation may be fatal.

In the event of electric shock, immediately switch off the electricity where practicable, and then pull
or push the patient clear. If the electricity cannot be switched off immediately, remember that the
patient is electrified until released and take precautions against receiving a shock yourself. The patient
must be pulled or pushed away from the conductor using any type of DRY insulating material, such
as wood, rope, clothing, rubber or plastic. DO NOT USE METAL OR ANYTHING MOIST. In
some cases, it may be easier to remove the conductor from the patient. Where necessary take care that
the patient does not sustain injury by falling.

Resuscitation
After rescue, if the patient is not breathing, commence artificial respiration immediately and
CONTINUE WITHOUT INTERRUPTION, FOR HOURS IF NECESSARY. When assistance is
available, send for a doctor and an ambulance.

Artificial respiration and cardiac massage

The need for artificial respiration is evident if the patient is not breathing, and it must begin
immediately. At the same time a check on the patient’s carotid pulse will establish the need for cardiac
massage. If no pulse can be felt, cardiac massage should proceed together with artificial respiration. The
techniques employed are described in detail in Australian Standards® AS 1674.2 Safety in welding and
allied processes – electrical, and also in the Trust publication module – ‘Resuscitation’ and other first aid
manuals.

Severe bleeding

Apply direct pressure to the wound by placing a large dressing over the wound and holding it in
position with a firm bandage. If the dressing becomes saturated with blood, do not remove it but apply
another. This will aid clotting. In an emergency, if a dressing is not readily available, firmly press the
sides of the wound together with the fingers or hand. Elevate the injured part to decrease the blood flow
to the wound. Seek medical attention immediately.

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Fractures
Do not move the patient, but immobilize the person and the fractured limb by use of pillows, blankets
or other suitable materials. Bleeding should be controlled if present, and the patient kept warm until
qualified medical help arrives.

Inhalation of toxic or intensively irritating gas or fumes

Remove the patient out of the danger zone at once and into fresh air. Place them in a warm comfortable
position. The patient should be taken to, or seen by, a doctor as quickly as possible. Where possible, the
gas or fumes involved should be identified to assist the doctor with tre

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Electricity and welding machines
Introduction
All arc welding processes have a few basic requirements for their operation. They must have a safe
voltage available that is sufficient for the operator to get the arc started and be maintained. They also
require sufficient amperage to provide the heat for melting of the parent metal and filler material.

Arc welding processes have been a popular and widely applied method of welding for many years.
They offer sound and reliable weld, simple operation and low capital cost.

In this chapter you will look at the following.

Arc welding process overview

 manual metal arc welding (MMAW)
 gas metal arc welding (GMAW)
 flux cored arc welding (FCAW)
 submerged arc welding (SAW)
 gas tungsten arc welding (GTAW)
Electricity and welding machines

 welding current
 current types
 welding machines
 amperage control
 machine characteristics
 selecting a welding power source.

At the end of this chapter, you will complete an activity

Arc welding process overview
There are a lot of arc welding processes used in the metal fabrication and welding industries.
Some of these are commonly used and others are used in specialist applications. This section
introduces some of the most commonly used arc welding processes; which are:
 manual metal arc welding (MMAW)
 gas metal arc welding (GMAW)
 flux cored arc welding (FCAW)
 submerged arc welding (SAW)
 gas tungsten arc welding (GTAW

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Manual metal arc welding (MMAW)

MMAW is a welding process that creates an electric arc between a hand held, flux-coated,
consumable filler wire and the work piece. The arc heat melts the parent metal and filler wire. The flux
coating breaks down in the arc to produce a gaseous shield that excludes atmospheric gases from the
weld zone. The flux coating also provides a de-oxidizing action and forms a slag on the cooling weld.

The MMAW welding process needs a suitable and constant current power source (AC or DC), a
handpiece, a work clamp, leads and flux-covered consumable electrodes.

MMAW equipment is cheap and simple to use and people with very little training and practice
are

able to use the MMAW process to make reliable welds. A skilled operator can use the MMAW

process to weld practically any material in virtually any situation.

Typical uses for the MMAW process include

• light/heavy/fabrication
• general engineering
• site work
• repairs.

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Gas metal arc welding (GMAW)
GMAW is a welding process that creates an electric arc between an automatically fed wire electrode
and the work piece. The arc heat melts the parent metal and filler wire. A supply of shielding gas that
excludes atmospheric gases from the weld zone is introduced around the arc.
The GMAW welding process needs a suitable and constant voltage power source (DC), a wire feed
unit, consumable wire electrodes, a shielding gas supply, a welding gun, a work clamp and leads.

GMAW equipment is not as cheap as MMAW and requires some skill to set up properly.
A good operator can use the GMAW process to weld most materials in most welding
positions.

Typical uses for the GMAW process include:

• light/heavy fabrication

• general engineering

• most materials and thicknesses.

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Flux-cored arc welding (FCAW)

FCAW is a welding process that creates an electric arc between an automatically fed, hollow wire
filled with flux and the work piece. The arc heat melts the parent metal, filler wire and flux. The flux
may also add additional material or elements and breaks down in the arc to produce a gaseous shield
that excludes atmospheric gases from the weld zone. An optional supply of shielding gas may be
introduced around the arc.

The FCAW welding process needs a suitable and constant voltage power source (DC), wire feed
unit, consumable flux-filled electrodes, an optional shielding gas supply, a welding gun, a work
clamp and leads.
FCAW equipment is generally more robust than GMAW plant and requires some skill to set up
properly. The process may be self-shielding or gas shielded.

Typical uses for the FCAW process include:

• heavy fabrication
• general engineering.
FCAW has a better deposition rate and fusion than GMAW

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Submerged arc welding (SAW)

SAW is a welding process that creates an electric arc between an automatically fed wire electrode and
the work piece. The arc heat melts the parent metal and filler wire. A supply of flux material is
introduced around the arc to contribute to the welding operation, exclude atmospheric gases from the
weld zone and form a slag over the cooling weld.

The SAW welding process needs a heavy duty power source (DC), a wire feed unit, wire electrodes, flux
and a flux delivery system, a power head unit, a welding gun, a work clamp and leads.

SAW equipment is heavy and specialized and generally produces high quality welds on
steel products.

Typical uses for the SAW process include:

• heavy/fabrication

• flat butt and fillet welds only.

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Gas tungsten arc welding (GTAW)

GTAW is a welding process that creates an electric arc between a non-consumable tungsten
electrode and the work piece. The arc heat melts the parent metal. A supply of inert shielding that
excludes atmospheric gases from the weld zone gas is introduced around the arc. Filler wire may be
introduced into the weld area.

The GTAW welding process needs a suitable and constant current power source (AC or DC),
tungsten electrodes, an inert shielding gas supply, a welding torch, a work clamp and leads.

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The GTAW equipment process requires some skill to set up properly and a
good operator can produce high quality welds on nearly all materials.

Typical uses for the GTAW process include:

• light fabrication

• general engineering

• root runs, pipe work.

GTAW welds most materials and thicknesses (carbon steel, aluminum, stainless steel
etc.)

There are other welding processes used in the metal fabrication industry that are
not covered in this text. These are:

• electric resistance welding (ERW)

• electroslag welding (ESW)

• laser welding (LW)

• fuel gas welding (FGW).

Fuel gas welding is covered in greater depth in gas welding theory.

Electricity and welding machines

All welding processes depend on three main requirements for their operation.

1. A heat or energy source – needed for fusion.

2. Atmospheric shielding – to prevent oxygen and nitrogen in the atmosphere

from contaminating the weld.

3. Filler metal – to provide the required weld build-up.

These factors are looked at more closely in later chapters dealing with the various
arc welding processes.

Welding current

To be suitable for welding, the current used must meet the following requirements.

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• There must be sufficient amperage to provide the heat for fusion.

• The voltage must be high enough to initiate the arc, but low enough to ensure
the safety of the welding operator.

• There must be a suitable means of current control.

Mains supply is unsuitable for use as the welding current as the voltage is too high
and the amperage too low. Mains supply must be ‘transformed’ to make it suitable
for use in welding. Alternatively, the welding current can be produced from a
dedicated welding generator or alternator.

Current types

Electric current may be either:

• alternating current (AC)

• direct current (DC).

Term Definition

an electric current that reverses direction in a circuit

alternating current (AC)
at regular intervals
direct current (DC) an electric current flowing in one direction only

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MEANING & USE OF SYMBOLS

An arc welding symbol consists of the main four parts 1. A reference line 2. An arrow. 3.
A basic welding symbol 4. A tail

The basic symbol indicates the type of weld.

The reference line is a line connected to the arrow. The position of the basic symbol
above or beneath this line determines the location of the weld. The reference line is always
drawn parallel to the bottom edge of the drawing, or to the base line of a particular

The arrow indicates the position of the weld; it is drawn at an angle from the end of the
reference line to one side of the joint. This side is called the „arrow side of the joint‟. The
opposite side is called the other side of the joint.

Welds on the „arrow side of the joint‟ are shown by inverting the weld symbol and placing it
beneath the reference line

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SYMBOL INDICATING FILLET WELD AT ARROW SIDE OF JOINT

Welds on the „other side of the joint‟ are shown by placing the symbols above the reference line.

Symbol indicating fillet welds on the other side of joint.

Welds on both sides of the joint are shown by placing the weld symbol above and below the
reference line.

Basic weld symbols describe the type of weld to be made. This symbol is a miniature drawing of
the metal’s edge preparation prior to welding. The basic weld symbol is only part of the entire
AWS welding symbol.

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The tail is added to the symbol only when special notes are required. A number or letter code
used inside the tail direct the welder to special notes located elsewhere on the drawing. These
notes may specify the heat treatment, welding process used, or other information not given on
the welding symbol.

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SUPPLEMENTARY SYMBOLS
Supplementary symbols can be placed above or below the basic symbol, or at the
intersection of the reference line and the arrow. Dimensions and reference to specifications, or
welding procedures may also be added.
Weld all around is a circle drawn on the welding symbol, indicating that the described
weld is to be made all around the part.

.Field weld symbol is a symbol added to the basic AWS welding symbol to indicate that a weld
is to be made at the job site (“ in the field”), rather than in a fabricating shop

Melt through is a complete joint penetration for a joint welded from one side and visible root
reinforcement is produced.

Backing symbol is an open rectangular box used in combination with a groove weld symbol
located on the reference line indicating that locating materials is required on the opposite side
control penetration.

Spacer symbol is an open box that intersects the reference line, indicating that a spacer is placed
between joint.

Contour and Finish Symbol

Flush contour symbol is located on the same side as the symbol and indicates the weld should be
approximately a flat plane with the surface.

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Convex contour symbol is located on the side as the symbol and indicates that the weld should
be raised or convex shape.

. Concave contour symbol is located on the same side as the symbol indicates that the weld
should be concave shape.

If the contour requires finishing, a finishing symbol will be sued in conjunction with the contour
symbol, a letter G indicate grinding, C indicate shipping, M indicate machining, and U indicate
unspecified which local method should be used.

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Weld preparation

Introduction

There are many types of joints and preparations used in welding, with the correct selection based on
a wide range of factors. Some of these are:

• welding process being used

• thickness of the material

• required strength of the weld

• accessibility – from each side

• positioning of the parts.

In this chapter you will look at the following.

 Selection of joint type

 fillet welds

 butt welds

 Points to remember

 welding terms and positions.

At the end of the chapter, you will complete an activity.

SELECTION OF JOINT TYPE

The type of joint depends on three factors:

• intensity of loading – butt welds are better able to transfer stress, however, when forces are essentially
static, as in buildings for example, fillet welds are usually the preferred type

• ease of welding – fillet welds are generally easier to make and require less operator skill

• cost – fillet welds are generally cheaper to produce as the cost of weld preparation for butt welds is
often considerable.

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Types of Joints
- Parts of weld joint
• Types of Weld
- Parts of Fillet Weld
- Parts of Groove Weld
- Edge Preparation

Welding Position

• Tee Joint
Tee welding joints are formed when two members intersect at a 90°
angle which makes the edges come together in the center of a plate
or component. Tee Joints are considered a type of fillet weld, and
can also be made when a pipe or tube is welded onto a base
plate. Extra care is required to ensure effective penetration into the
roof of the weld.

Welding Styles Used To Create T-Joints

 Plug weld
 Fillet weld
 Bevel-groove weld
 Slot weld
 Flare-bevel-groove weld
 J-groove weld
 Melt-through weld

Lap Joint

Lap welding joints are used most often to joint two pieces with differing
thicknesses together. Also considered a fillet type, the weld can be made
on one or both sides. A Lap Joint is formed when 2 pieces are placed in
an over lapping pattern on top of each other

Welding Styles Used To Create Lap Joints:

 Slot weld

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 Plug weld
 Bevel-groove weld
 Spot weld
 Flare-bevel-groove weld
 J-groove weld

Edge Joint

Edge welding Joints are often applied to sheet metal

parts that have flanging edges or are placed at a
location where a weld must be made to attach to
adjacent pieces. Being a groove type weld, Edge
Joints, the pieces are set side by side and welded on
the same edge. For heavier applications filler metal
is added to melt or fuse the edge completely and to
reinforce the plate.

Welding Styles Used To Create

Corner Joints:
 Spot weld
 Fillet weld
 V-groove weld
 Square-groove weld or butt weld
 U-groove weld
 Bevel-groove weld
 Flare-V-groove weld
 J-groove weld
 Corner-flange weld.

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 Edge wel

Butt Joint
Being the universally accepted method for attaching a pipe to
itself it’s also used for valves, flanges, fittings, and other
equipment. A butt welding joint is also known as a square
grove weld. It’s the easiest and probably the most common
weld there is. It consists of two flat pieces that are side by side
parallel. It’s a very affordable option
Welding Styles Used To Create Butt
Joints:
 Bevel-groove butt weld
 Square-groove butt weld
 V-groove butt weld
 U-groove butt weld
 J-groove butt weld
 Flare-bevel-groove butt weld
 Flare-V-groove butt weld

Fillet Welded Joints

Fillet Welded Joints are just another terminology for corner, lap, and tee joints. Fillet Welded
Joints are the most common type of welding joint and accounts for nearly 75% of joints made with
arc welding. You do not need to prepare the edge and this type of joint make it easy to weld piping
systems. Butt welds are more expensive than fillet welds. Fillet welds are mostly used in piping
systems to join pipe to socket joints.

Joint Preparation
Welding joints can be prepared in numerous ways including:
 Casting
 Shearing
 Machining
 Forging
 Filing
 Stamping
 Oxyacetylene cutting (thermal cutting process)
 Routing
 Grinding
 Plasma arc cutting (thermal cutting process)

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4 Basic Welding Positions

 Flat Position (1G and 1F)
 Horizontal Position (2G and 2F)
 Vertical Position (3F and 3G)
 Overhead Position

DIFFERENCE OF FILLET AND GROOVE

Fillet welding refers to the process of joining two
pieces of metal together whether they be
perpendicular or at an angle. These welds are
commonly referred to as Tee joints which are two
pieces of metal perpendicular to each other or Lap
joints which are two pieces of metal that overlap
and are welded at the edges.

The groove weld. ... A weld groove is defined

as “A channel in the surface of a workpiece or
an opening between two joint members
providing space to contain weld metal.” Groove
welds fill the space made between sections of
the workpiece.

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Flat Position (1G and 1F)

The easiest type to perform is the flat
position, which is also sometimes called the
downhand position. It involves welding on
the top side of the joint. In this position, the
molten metal is drawn downward into the
joint. The result is a faster and easier weld.
In 1G and 1F, the number 1 refers to the flat
position, while the letter G stands for a
groove weld and letter F stands for a fillet
weld.

Horizontal Position (2G and 2F)

This is an out of position welding position.
It’s a more difficult position compared to the
flat position and it requires more skill from
the welding operator to do them well.
2G is a groove weld position that involves
placing the weld axis in a horizontal plane
or approximately horizontal. As for the face
of the weld, it should lie in an approximately
vertical plane.
2F is a fillet weld position, in which the
welding is done on the upper side of the
surfaces that is approximately horizontal
that lies against a surface that is
approximately vertical. In this position, the
torch is usually held at a 45-degree angle.

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Vertical Position (3F and 3G)
In this position, both the plate and the weld lie
vertically or almost vertically. The 3F and 3G
refer to vertical fillet and vertical groove
positions.
When welding vertically, the force of gravity
pushes the molten metal downward and so it has
the tendency to pile up. To counteract this, you
can use either an upward or downhill vertical
position.
To control this in the upward vertical position,
point the flame upward, holding it at a 45-degree
angle to the plate. This way, the welder will use
the metal from the lower parts of the workpiece
to weld against the force of gravity. In the
downhill position, the metal from the upper parts
and the electric arc’s kinetic force are used.

Overhead Position
In this position, welding is carried from the underside of
the joint. It’s the most complicated and difficult position
to work in. The 4G and 4F positions stand for groove and
fillet welds respectively.
In the overhead position, the metal deposited to the joint
tends to sag on the plate, resulting in a bead with a higher
crown. To prevent this, keep the molten puddle small. If
the weld puddle becomes too large, remove the flame for
a moment in order to allow the molten metal to cool.
The positions flat, horizontal, vertical and overhead are
the basic types of welding positions. However, they do
not adequately describe pipe welding positions. Pipe
welding can be done under many different requirements.
These positions we’ll cover in a separate article.

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Weld Parts

Fillet welds

A fillet weld is a weld approximately triangular in cross-section, lying external to the planes of
the parts being joined.

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FILLET WELD CONFIGURATION

The weld configuration relates to the relationship of the plates to be joined. The joint
types may be tee fillet, outside corner or lap and these may be made in various positions, eg flat,
vertical.

LAP JOINTS
The minimum overlap for parts carrying stress is five times the thickness of the thinner part
joined. Both ends of the lap require welding.

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FILLET WELD PROFILE

Three fillet profiles are possible. A perfect fillet weld would be the right size and equal leg,
have an even front face and described as miter-shaped. An over-welded fillet weld or a weld that
has excess reinforcement and abrupt transition at the toes that may cause stress concentration, is
described as convex. A weld that has a reduced throat distance compared to a leg size is described
as concave (this may cause centerline cracking or weld failure).

Ideally, fillet welds should be slightly convex. It should be noted that concave fillet welds
require longer leg lengths to meet the requirements of nominal size .

FILLET WELD SIZE

The amount of fillet weld required to obtain the necessary strength may be specified in one
of two ways.

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1. Nominal size – the length of the leg of a triangle which can be inscribed wholly within the
cross-section of the weld and the throat thickness, which must be 0.7 of the leg lengths. Where a
gap exists in the root of the joint, a reduction in the nominal size may be made

Where the amount of weld required is specified on an engineering drawing by nominal size, the
length of weld of the required size will be stated. eg 200 mm of 6 mm fillet

2. Effective area – the amount of weld required may also be expressed in terms of effective area.
The effective area of a weld is the effective length multiplied by the design throat thickness
(DTT). The effective length (EL) is the length of the weld which is on the specified size.

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Intermittent fillet welds
There are many applications where the required strength can be achieved without the need
for a continuously welded joint. Where this is the case it is common to use intermittent fillet welds.
There are two types of intermittent fillet welds: chain or staggered.

Any section of intermittent fillet welding shall have an effective length of not less than
four times the weld size with a minimum length of 40 mm.

The clear spacing between the effective lengths of each weld carrying stress shall not exceed the
following number of times the thickness of the thinner part joined.

 16 times for compression.

 24 times for tension, and in no case be more than 300 mm.

Chain intermittent welding is preferred to staggered intermittent welding. Where staggered

intermittent welding is used, the welds on each side of the parts joined shall be continued to the
end of the part.

Butt welds
Butt welds are used to join metal products such as sheet, plate, rolled and pressed
sections. This type of joint has the advantage of having high strength without changing the
profile of the structure. Butt welds are better able to transfer stress than fillet welds and are
preferred for live or cyclic loading.

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Industrial uses for butt welds include:
 boiler and pressure vessel construction
 ship building
 earth moving equipment
 aircraft and submarines

BUTT WELD TERMINOLOGY

 The terminology that applies to the parts of a fillet weld applies equally to butt welds,
 with the major difference being design throat thickness, which in a full penetration butt
 weld is equal to the plate thickness.
 The terms concerned with the preparation for butt welds require explanation at this
 stage.

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PREPARATION OF PLATE EDGES FOR BUTT WELDS

In most cases, especially when joining metal of considerable thickness, it is difficult to
produce satisfactory butt welds unless the edges to be joined are adequately prepared. Sheet metal
and thin plate may be welded without preparation (up to 5 mm thick), but for metal over 6 mm in
thickness the edges must be prepared in such a way as to provide a ‘V’ or ‘U’ shaped groove in
which the weld metal is deposited, so allowing complete fusion or penetration through the full
thickness of the metal.

Failure to properly prepare the edges may lead to the production of faulty welds, as the
correct manipulation of the electrode may be impeded and/or the desired degree of penetration
may not be achieved. Plates which have been cut by shearing should have all burrs and
irregularities removed before welding.

Plates prepared for welding by oxy-flame cutting techniques should have an even surface,
free from notches or grooves. For this reason, machine flame-cut surfaces are preferred to hand
flame-cut surfaces. Imperfections on beveled edges may be removed by filing or grinding.
Preheating may be required when oxy-flame cutting weld preparation on hardened steel,
particularly if thick. ‘U’ and ‘J’ preparations may be carried out by means of oxy-flame gouging,
but usually such forms of beveling are prepared by machining the parts.
Weld preparation is commonly applied by:
 shearing
 grinding
 machining
 oxy-flame or plasma cutting

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 arc or oxy-flame gouging

Edge preparation and specification

The various types of edge preparation in common use for the welding of steels are as follows.

Closed square butt joint – The edges are not prepared and are fitted together without a
gap. This preparation is suitable for steel up to 3 mm thick and is welded from both sides.

Open square butt joint – The edges are not prepared but are separated slightly to allow fusion
through the full thickness of the plate. The gap is equal to half the plate thickness, to within 1.5
mm. Suitable for steel up to 6 mm in thickness, but must be welded from both sides

Open square butt joint with permanent backing material – This type of joint is used when
welding plates up to 6 mm thick, where welding is possible from one side only. The gap is equal
to the plate thickness. Complete fusion of the weld into the backing material must be obtained.

Single vee butt joint – Used on steel up to 12 mm thick and on metal of greater thickness, where
access from both sides is difficult. Where possible the back bof the first run must be cleaned out
and the job completed by deposition of a backing run

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Single bevel butt joint – Applications for single bevel butt joints are as for single n‘V’ joints
described previously.

Double vee butt joint – Used on plate 12 mm and over when welding can be applied from both
sides. It allows a reduction in weld metal compared to a single ‘V’ preparation on the same
thickness of steel. This type of preparation also tends to minimize distortion as the weld contraction
is equal on each side of the joint.
Not economical on steel over 50 mm thick.

Double bevel butt joint – Applications for double bevel butt joints are as for double ‘V’ joints
described previously.

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Backing runs
 Backing material is used to support the root run of a butt weld, or to provide a sound
weld through the full plate thickness, when access is possible from one side only.
 To help reduce weld deposition rates complete penetration butt welds are often welded
from both sides. The back of the first root run should be gouged and/or ground to clean
metal to ensure complete penetration of the other side run.

Backing material
 Permanent backing material is known as a backing strip. Temporary backing material is
known as a backing bar.
 Backing strips are fused into the weld and should: be no less than 3 mm thick and be of
sufficient size to ensure they do not burn through
 have weldability not less than that of the parent metal fit as close as possible with a
maximum gap between the parent metal and the backing strip of 1.5 mm.

Points to remember
 Test welds should be carried out to ensure the suitability of amperage/root face/ gap
combinations. Frequent tacks and a consistent gap should be used.
 For economy, an electrode of the largest possible size should be employed and where
possible welding carried out in the down hand position.
 Small variations in gap or root face dimensions can significantly affect penetration and
fusion in the root of a joint. Accuracy and consistency of weld preparation and fit-up is
essential

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WELDING TERMS AND POSITIONS

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DIFFERENT PIPE POSITION USING PIPE

1G Position
In the 1G welding position, the pipe is in the
horizontal position and can be rotated along the
horizontal (X) axis. The welder's position remains
stationary. Welding is performed on the top of the pipe.
This is the most basic welding position that can be
performed.

2G Position
In the 2G welding position, the pipe is in the
vertical position and can be rotated along the
vertical (Y) axis. The welder's position remains
stationary. Welding is performed on the side of the
pipe in a horizontal direction.

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5G Position

In the 5G welding position, the pipe is in the

horizontal position. Unlike the 1G position, the
pipe is in a fixed position and it cannot be
rotated. The welder moves around the pipe in
the vertical direction to perform the welding.

6G Position
In the 6G welding position, the pipe slopes
at approximately 45° from the horizontal
(X) axis or 45° from the vertical (Y) axis.
The pipe is in a fixed position, so the welder
must move around the pipe to perform the
welding. This is an advanced welding
position that requires a great deal of
experience and technical expertise

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Manual metal arc welding (MMAW)
Introduction
Manual Metal Arc Welding (MMAW) is one the earliest of the arc welding processes,
but has remained popular despite the introduction of newer and more sophisticated processes.
Indeed, this lack of sophistication is one of the major attractions of the process.

In this chapter you will look at the following.

The process
 applications
 advantages
 limitations

 Equipment
 MMAW variables
 amperage
 angle of approach
 angle of travel

 MMAW faults
 MMAW electrodes
 functions of flux coating
 types of coating
 care of electrodes
 electrode deterioration
 storage of electrodes
 redrying of electrodes
 electrode classification.

At the end of the chapter, you will complete an activity

The process
The MMAW process operates as follows. A low voltage, high amperage current flows to create
an arc between the tip of the electrode and the work piece. This generates the heat for welding
and causes the work piece and the tip of the electrode to melt

The flux coating on the electrode decomposes (burns) due to the intense heat of the arc
and generates a gaseous shield, which protects the weld pool and surrounding hot metal from the
atmosphere.

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The electrode melts off and is transferred across the arc in the form of droplets. The
molten metal provided by the electrode adds to the molten parent metal and they become the
weld metal when solidified.

Molten electrode flux which is transferred across the arc acts as a scavenger, picking up
impurities from the surface of the parent metal. The slag which forms covers the weld pool,
solidifies, and protects the hot weld metal as it cools.

The flux ingredients provide arc ionization (the air gap between the tip of the electrode
becomes electrically conductive), enabling the use of alternating current.

Applications of the process

Many welding operators have grown up using the MMAW process. This familiarity and
the fact that it is simple to set up and use, makes it first choice for selection in many instances.
The low cost of equipment makes the process accessible to most people, and MMAW has no
special requirements such as external gas shielding or high-frequency arc initiation. Sound welds
are easily produced and the process doesn’t tend to result in weld defects such as lack of fusion
which is common in GMAW.
MMAW is widely used for:

 structural work
 pressure vessels
 piping
 maintenance welding
 site construction
 general fabrication.
Advantages of the process

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The advantages of the MMAW is its versatility and the availability of a wide range of
consumables. Set-up time is short, making the process ideal for small jobs, short production runs,
and where the welding is carried out on site.
MMAW offers the following advantages over other welding processes:
 low capital cost for equipment
 versatility across a wide range of applications
 simple, reliable equipment
 low maintenance of equipment
 ideal for site work
 wide operator appeal
 sound, reliable welds.
Limitations of the process
Although faster than some welding processes, MMAW has lower deposition rates than many of
the newer welding processes that use a higher current. The process has a low operator duty cycle,
with the operator spending a lot of time changing electrodes and chipping slag. These two factors
combine to limit the application of this process, especially if high production rates are required.

Equipment
Equipment for manual metal arc welding consists of the following.
 Power source – usually a constant-current type output transformer or transformer
rectifier is used, although various other types of power sources, such as generators or
inverters can also be used. The function of the power source is to supply welding current
with sufficient amperage to provide the necessary heat, at a voltage which is safe to use.
 Electrode handpiece and lead – to carry current to the arc via the electrode.
 Work return lead – connects the work piece to the power source thereby completing the
welding circuit. (A closed circuit is necessary for current flow ).

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MMAW variables
The major variables of the MMAW process are:
 amperage
 arc length
 travel speed
 angle of approach
 angle of travel
Amperage
 An increase in amperage will:
 increase the heat of the welding arc
 increase fusion and penetration
 give a higher deposition rate
 increase arc force
 enable easier arc starting
 give a more fluid weld pool
 increase spatter
 increase emission of ultra violet radiation.

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A decrease in amperage will have the opposite effect.
As the size and thickness of the metal to be welded increases, so the heat required for fusion
increases, necessitating higher amperages. Also the higher the heat input, the slower the cooling
rate of the weld zone. Slow cooling rates are generally desirable when welding most metals
A simple equation is: VOLTAGE x AMPERAGE = HEAT
Angle of approach
Another simple rule for welders is that the metal goes were you point the electrode.
Following that rule, it can be seen in the fillet weld example below that to get an even weld build
up, the electrode must be pointed evenly at both plates, ie 45° and the welding arc is ‘directional’,
that is metal transfer is essentially along the line of the electrode

Unless attention is given to the angle of approach, defects such as slag inclusions, lack of fusion
and penetration, and unacceptable weld contours may result.
Angle of travel
The angle of travel is established essentially as a means of keeping the molten weld pool behind
the arc, and preventing the slag from catching up to the electrode and causing slag inclusions.
Although the angle of travel is commonly set at 60–70° many factors such as amperage, electrode
type, and travel speed will determine the actual angle used. It should be noted however that the
angle of travel used should be the minimum required for slag control, as laying the electrode too
flat causes problems such as poor appearance, excessive spatter, reduced penetration, and a narrow,
convex bead shape

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MANUAL METAL ARC WELDING FAULTS
The defects commonly encountered in MMAW are:

 weld cracking
 porosity
 slag inclusions
 lack of fusion
 insufficient or excessive penetration
 contour faults
 undercut
 excessive spatter
 stray arcing.

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Manual metal arc welding (MMAW) electrodes

The manual metal arc welding electrode consists of a core of wire surrounded by a flux coating.
The wire is generally of similar composition to the metal to be welded. The flux is applied to the
wire by the process of extrusion. For welding carbon and low alloy steels (the metals most
commonly fabricated using the MMAW process) electrodes will have one of four flux types,
either:

 cellulose type coating

 rutile type coating
 hydrogen controlled coating (low hydrogen)
 iron powder type coating.

The flux coatings (from which the electrode types take their name) account for the major
differences between electrode types.
The ingredients of the flux coating are carefully controlled so as to give desirable running
characteristics and weld metal properties.
Among these desirable running characteristics are:

 arc stability
 ease of striking
 elimination of porosity
 minimum spatter
 elimination of noxious fumes and odours
 a tough durable coating
 control of penetration
 high deposition rates
 desirable physical and mechanical weld metal properties

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The aforementioned list is by no means exhaustive and many characteristics are incompatible, eg
deep penetration and minimum spatter. Therefore when choosing an electrode for use,
compromises must be made.
The choice of an electrode for a particular application depends upon:
 the composition of the parent metal
 the size and thickness of the parent metal
 the mechanical properties required of the weld metal
 the physical properties required of the weld metal
 the welding position
 the amount of penetration required
 the amount of spatter allowable
 available welding current
 deposition rate required
 appearance
 cost
 slag detachability
 weld contour and size
 fluidity of the slag
 operator appeal.

Functions of the flux coating

In the early days of arc welding, bare wire electrodes were used. The results obtained from these
electrodes left much to be desired. Over the years, electrodes have improved and flux coatings
have evolved to the stage where the deposited weld metal, in many cases, has better
metallurgical properties than the parent metal.

The flux coating of the electrode has many functions. It:

 provides a gaseous shield to protect the weld from atmospheric contamination

 provides arc ionization. This gives a stable arc and enables the use of AC
 controls the chemical composition and properties of the deposited weld metal
 controls the deposition rate
 controls spatter
 influences the degree of penetration
 provides slag which performs the following functions:
 forms a protective cover over the weld metal to prevent the formation of
 oxides while the weld metal is cooling
 acts as a scavenger to remove oxides and impurities from the weld
 helps to produce the correct bead shape and improve weld appearance
 slows the cooling rate of the weld metal
 enables ‘positional’ welding.

Some of the ingredients used in flux are:

 wood pulp (cellulose), titanium dioxide (rutile), limestone, fluorspar, silica, and
 feldspar – for producing slag and shielding gas
 ferro-manganese and ferro-silicon – used as deoxidisers
 potassium and sodium silicates, used as binders
 clays and gums – used as binders

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 ferro-chromium, ferro-molybdenum and nickel powder – for alloying
 iron powder and iron oxide – to increase deposition.

Electrode coating types

As shown above, there are five basic electrode coating types used to make electrodes nfor the
welding of carbon and low alloy steels.

These coating types are then arranged into four basic electrode types or groups, which are:
 cellulose
 rutile
 hydrogen-controlled
 iron powder.

The Classification system consists of the following, as per ISO 2560B.

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EXX10 and EXX11 electrodes (E4310, E4311, E4910)

Electrodes of EXX10 and EXX11 classification have thin coatings which contain at least
15% cellulose and up to 30% titania as rutile or titanium white. Cellulose electrodes operate with
a forceful, deeply penetrating spray type arc with fairly high spatter.

As a result of the decomposition of the cellulose material, a voluminous gas shield is

formed around the arc region, protecting the weld metal from atmospheric contamination. The
slag is very fluid, thin, friable and easily removed when cold, but may not appear to completely
cover the deposit.

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An example of an electrode of this electrode of this classification is shown below.

Importantly, the end of this classification contains the following.

A suffix – the suffix consists of a letter (or letters) followed by a numeral. The
letters denote the type of weld metal which the electrode deposits. eg: N3 = Ni mass % 1,
5
Numerals – the numerals are used to give an indication of the percentage of alloy addition. As
the percentage increases, so does the magnitude of the suffix numeral. The numerals range from
one through five.

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How Much Have You Learned?

Objectives: After studying of shielded metal arc welding the student’s will able to

 Discuss and illustrate the parts and operation of Shielded Metal Arc Welding
 Identify and explain the five basic welding joints
 Identify and describe the various weld that may be used in each welding joints
 Label the parts or areas of a groove and fillet welds
 Locate and apply required weld and joint information from an AWS welding symbols
 Describe and draw the welding position
 Draw the different weave motion of electrode
 Identify the defects of welding

What is Shielded Metal Arc Welding?

______________________________________________________________________________
______________________________________________________________________________
______________________________________________________________________________
______________________________________________________________________________
______________________________________________________________________________
______________________________________________________________________________
______________________________________________________________________________
Illustrate, explain and Identify the parts and of welding machine?

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Illustrate and explain the Five Basic Welding Joints
BUTT JOINT-
______________________________________________________________________________
______________________________________________________________________________
______________________________________________________________________________
______________________________________________________________________________
______________________________________________________________________________
______________________________________________________________________________
______________________________________________________________________________
______________________________________________________________________________
______________________________________________________________________________
______________________________________________________________________________
______________________________________________________________________________
__________________________________________

TEE JOINT-
______________________________________________________________________________
______________________________________________________________________________
______________________________________________________________________________
______________________________________________________________________________
______________________________________________________________________________
______________________________________________________________________________
______________________________________________________________________________
______________________________________________________________________________
______________________________________________________________________________
______________________________________________________________________________
______________________________________________________________________________
_________________________________________

LAP JOINT-
______________________________________________________________________________
______________________________________________________________________________
______________________________________________________________________________
______________________________________________________________________________
______________________________________________________________________________
______________________________________________________________________________
______________________________________________________________________________
______________________________________________________________________________
______________________________________________________________________________
______________________________________________________________________________
______________________________________________________________________________
__________________________________________

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CORNER JOINT-
______________________________________________________________________________
______________________________________________________________________________
______________________________________________________________________________
______________________________________________________________________________
______________________________________________________________________________
______________________________________________________________________________
______________________________________________________________________________
______________________________________________________________________________
______________________________________________________________________________
______________________________________________________________________________
______________________________________________________________________________
___________________________________________

JEDGE JOINT-
______________________________________________________________________________
______________________________________________________________________________
______________________________________________________________________________
______________________________________________________________________________
______________________________________________________________________________
______________________________________________________________________________
______________________________________________________________________________
______________________________________________________________________________
______________________________________________________________________________
______________________________________________________________________________
______________________________________________________________________________
_________________________________________

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Identify the Parts of Weld

Weld Symbols and Supplementary Symbols

GROOVE

SQUARE SCARF V BEVEL U J FLARE V FLARE

BEVEL

FILLET PLUG/ STUD SPOT/ SEAM BACK/ SURFACING EDGE

SLOT PROJECTION
BACKING

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CONTOUR

WELD FIELD MELT CONSUMABLE BACKING OR FLUSH CONVEX CONCAVE

ALL WELD THROUGH INSERT SPACER OR FLAT
AROUND (SQUARE) (RECTANGLE

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Illustrate the different diagram of weave motion of electrode

CIRCULAR SQUARE C

STRAIGHT STEPPED J T

ZIGZAG V UPSIDE DOWN V

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Write the specification of electrode

Discuss the different types of welding defects

DEFECTS WHY WHAT TO DO

POROUS WELD

POOR PENETRATION

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WARPING

UNDERCUT/UNDERFILL

DISTORTION

CRACKED WELD

POOR APPEARANCE

POOR FUSION

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BRITTLE WELD

SPATTER

MAGNETIC BLOW

WELD STRESS

SLAG INCLUSION

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OVERLAP

EXCESSIVE CONVEXITY

EXCESSIVE CONCAVITY

 Draw the isometric weld position of weld carbon plate using SMAW 1G, 2G, 3G,4G
position
 Draw the isometric weld position of weld carbon pipe using SMAW 1G, 2G, 3G, 4G,
5G, 6G position

REFERENCES
Welding Technology, Second Edition by Gower A. Kennedy
Welding Inspection Technology, Education Department, American welding Society
Welding Principles and Application by Larry Jeffus and Harold V. Johnson

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