9/10

TLE-IA-SMAW
Quarter 2 – Module 2:
Check Root Pass Penetration in
Accordance with Acceptable Standards
TLE-IA-SMAW–Grades 9/10
Alternative Delivery Mode
Quarter 2 – Module 2: Check Root Pass Penetration in Accordance with
Acceptable Standards
First Edition, 2020

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Development Team of the Module

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 9/10

TLE-IA-SMAW
Quarter 2 – Module 2:
Check root pass penetration in
accordance with acceptable
standards
Introductory Message
For the facilitator:

Welcome to the Shielded Metal Arc Welding – Grades 9/10 Alternative Delivery
Mode (ADM) Module on Check root pass penetration in accordance with
acceptable standards)

This module was collaboratively designed, developed and reviewed by

educators both from public and private institutions to assist you, the teacher
or facilitator in helping the learners meet the standards set by the K to 12
Curriculum while overcoming their personal, social, and economic
constraints in schooling.

This learning resource hopes to engage the learners into guided and
independent learning activities at their own pace and time. Furthermore, this
also aims to help learners acquire the needed 21st century skills while taking
into consideration their needs and circumstances.

In addition to the material in the main text, you will also see this box in the
body of the module:

Notes to the Teacher

This contains helpful tips or strategies that
will help you in guiding the learners.

As a facilitator, you are expected to orient the learners on how to use this
module. You also need to keep track of the learners' progress while allowing
them to manage their own learning. Furthermore, you are expected to
encourage and assist the learners as they do the tasks included in the module.

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For the learner:

Welcome to the Shielded Metal Arc Welding – Grades 9/10 Alternative Delivery
Mode (ADM) Module on Check root pass penetration in accordance with
acceptable standards!

This module was designed to provide you with fun and meaningful
opportunities for guided and independent learning at your own pace and time.
You will be enabled to process the contents of the learning resource while
being an active learner.

This module has the following parts and corresponding icons:

This will give you an idea of the skills or

What I Need to Know competencies you are expected to learn in the
module.

This part includes an activity that aims to

check what you already know about the
What I Know
lesson to take. If you get all the answers
correct (100%), you may decide to skip this
module.
This is a brief drill or review to help you link
What’s In the current lesson with the previous one.

In this portion, the new lesson will be

What’s New introduced to you in various ways; a story, a
song, a poem, a problem opener, an activity
or a situation.
This section provides a brief discussion of the
What is It lesson. This aims to help you discover and
understand new concepts and skills.

This comprises activities for independent

practice to solidify your understanding and
What’s More
skills of the topic. You may check the
answers to the exercises using the Answer
Key at the end of the module.
This includes questions or blank
What I Have Learned sentence/paragraph to be filled in to process
what you learned from the lesson.
This section provides an activity which will
What I Can Do help you transfer your new knowledge or skill
into real life situations or concerns.

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 This is a task which aims to evaluate your
Assessment level of mastery in achieving the learning
competency.
In this portion, another activity will be given
Additional Activities to you to enrich your knowledge or skill of the
lesson learned.

Answer Key This contains answers to all activities in the

module.

The following are some reminders in using this module:

1. Use the module with care. Do not put unnecessary mark/s on any part
of the module. Use a separate sheet of paper in answering the exercises.
2. Don’t forget to answer What I Know before moving on to the other
activities included in the module.
3. Read the instruction carefully before doing each task.
4. Observe honesty and integrity in doing the tasks and checking your
answers.
5. Finish the task at hand before proceeding to the next.
6. Return this module to your teacher/facilitator once you are through
with it.
If you encounter any difficulty in answering the tasks in this module, do
not hesitate to consult your teacher or facilitator. Always bear in mind that
you are not alone.

We hope that through this material, you will experience meaningful

learning and gain deep understanding of the relevant competencies. You
can do it!

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 What I Need to Know

Learning Objectives:

At the end of the lesson you should be able to:

✓Check root pass penetration in accordance with acceptable standards.
✓ Appreciate the importance of root pass penetration with acceptable standards.
✓ Perform the root pass penetration in accordance with acceptable standards.

What I Know

Directions: Read the statement carefully and identify what is being described or
defined. Choose your answer from the words inside the box.

Lack of fusion lack of or incomplete penetration Undercut

Porosity Inclusions

___________ 1. Is when the weld fails to fuse one side of the joint in the root.
Incomplete root penetration occurs when both sides root region of the joint
are unfused.
___________ 2. Occur in the form of a rolled over bead crown. Again, it is
generally caused by a very low travel speed and attempting to make too large
a weld in a single pass.
___________ 3. Is caused by the absorption of nitrogen, oxygen and hydrogen
in the molten weld pool which is then released on solidification to become
trapped in the weld metal.
___________ 4. Is one of the welding defects that are usually easily visible in
the weld. Is a vitreous material that occurs as a byproduct of stick welding,
flux-cored arc welding and submerged arc welding.
___________ 5. This welding imperfection is the groove formation at the weld
toe, reducing the cross-sectional thickness of the base metal. The result is the
weakened weld and workpiece.

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 What’s In

Directions: Match the Picture in column B with their corresponding meaning

in column A. Write the letter of your answer on the space provided before each
number.

Column A Column B
A.
_______ 1. Travel Speed

B.
_______ 2. Electrode Size

C.

_______ 3. Arc Length

D.
_______ 4. Electrode Angle

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 What’s New

Introduction:
As the presence of imperfections in a welded joint may not render the
component defective in the sense of being unsuitable for the intended
application, the preferred term is imperfection rather than defect. For this
reason, production quality for a component is defined in terms of a quality
level in which the limits for the imperfections are clearly defined, for example
Level B, C or D in accordance with the requirements of BS EN ISO 5817. For
the American standards ASME IX and AWS D1.1, the acceptance levels are
contained in the standards.
Imperfections can be broadly classified into those produced on fabrication of
the component or structure and those formed as result of adverse conditions
during service. The principal types of imperfections are:
Fabrication:
● Lack of fusion
● Lack of or incomplete penetration
● Undercut
● Porosity
● Slag Inclusions

Welding procedure, joint features and access and welder technique will have
a direct effect on fabrication imperfections. Incorrect procedure or poor
technique may produce imperfections leading to premature failure in service.

Lack of fusion - Lack of fusion

imperfections can occur when
the weld metal fails:
● To fuse completely with the
sidewall of the joint.
● To penetrate adequately the
previous weld bead.

Prevention:
• Use a sufficiently wide joint
preparation
● select welding parameters (high
current level, short arc length,
not too high a welding speed) to

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promote penetration into the
joint side wall and previously
deposited weld runs without
causing flooding
● ensure the electrode/gun angle
and manipulation technique will
give adequate side wall fusion
● use weaving and dwell to
improve side wall fusion
providing there are no heat input
restrictions
● if arc blow occurs, reposition
the current return cable clamp,
use AC (in MMA welding) or
demagnetize the steel
Lack of or incomplete
penetration - Incomplete root
fusion is when the weld fails to
fuse one side of the joint in the
root. Incomplete root penetration Fig.1a
occurs when both sides root
region of the joint are unfused.

Typical imperfections can arise in Fig. 1b

the following situations:

● An excessively thick root face in

a butt weld (Fig. 1a)
● Too small a root gap (Fig. 1b) Fig. 1c
● Misplaced welds (Fig. 1c)
● Failure to remove sufficient
metal in cutting back to sound
metal in a double sided weld (Fig.
1d) Fig. 1d
● Incomplete root fusion when
using too low an arc energy (heat)
input (Fig. 1e)
● Too small a bevel angle,
too large a diameter electrode in Fig. 1e
MMA welding (Fig 2)
Prevention:
● Do not use too large a root face
or too small a root gap and Fig. 2
ensure the welding current is
sufficient for the weld pool to
penetrate fully the root

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● Use the correct current level
and not too large an electrode
diameter for the root run
● Use a sufficiently high welding
current level which is supported
by the appropriate arc voltage for
the application
● When using a joint
configuration with a root gap,
make sure it is of adequate width
and does not close up during
tacking and subsequent welding
● Do not use too low a current
level causing the weld pool to
bridge the root gap without fully
penetrating the root.
Undercut - This welding
imperfection is the groove
formation at the weld toe,
reducing the cross-sectional
thickness of the base metal. The
result is the weakened weld and
workpiece.
Prevention:
● Use proper electrode angle.
● Reduce the arc length.
● Reduce the electrode’s travel
speed, but it also shouldn’t be too
slow.
● Choose shielding gas with the
correct composition for the
material type you’ll be welding.
● Use of proper electrode angle,
with more heat directed towards
thicker components.
● Use of proper current, reducing
it when approaching thinner
areas and free edges.
● Choose a correct welding
technique that doesn’t involve
excessive weaving.
● Use the multi-pass technique

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Porosity - occurs as a result of
weld metal contamination. The
trapped gases create a bubble-
filled weld that becomes weak
and can with time collapse.
Prevention:
● Clean the materials before you
begin welding.
● Use dry electrodes and
materials.
● Use correct arc distance.
● Check the gas flow meter and
make sure that it’s optimized as
required with proper with
pressure and flow settings.
● Reduce arc travel speed, which
will allow the gases to escape

Slag Inclusion - is one of the

welding defects that are usually
easily visible in the weld. Slag is
a vitreous material that occurs as
a byproduct of stick welding,
flux-cored arc welding and
submerged arc welding. Is can
occur when the flux, which is the
solid shielding material used
when welding, melts in the weld
or on the surface of the weld
zone.

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 What Is It
Welding and Defect Acceptance

During offshore line installation, the occasional weld defect repair may be
carried out just after the stern most tensioner and before the next roller
support in the repair station. The local stresses at the weld repair are
intensified during the weld excavation process. Defects exceeding the project
criteria are thoroughly removed; however, the removal of excess material
should be minimized to minimize local stresses. The determination of safe
weld excavation sizes for repair is one of the more difficult evaluations in line
installation engineering. This subject has attracted much attention because
of personnel safety and the risk of the pipeline parting or buckling on the
ramp during excavation. This chapter presents an analytical method of
determining safe weld excavation lengths, preventing both plastic collapse
and fast fracture of the pipe during weld defect repair.

What’s More

Multiple Choice

Instruction: Read the questions carefully and choose the correct answer in
the choices below.

Note: Use Intermediate paper only.

1. Fusion imperfections can occur when the weld metal fails to fuse
completely with the sidewall of the joint.
A. Incomplete Penetration C. Lack of penetration
B. Lack of fusion D. Incorrect Current

2. Is a vitreous material that occurs as a byproduct of stick welding, flux-

cored arc welding and submerged arc welding. Is can occur when the
flux, which is the solid shielding material used when welding, melts in
the weld or on the surface of the weld zone.
A. Porosity C. Incorrect Current
B. Undercut D. Slag Inclusion

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 3. Root fusion, is when the weld fails to fuse one side of the joint in the
root.
A. Lack of or incomplete Penetration C. Undercut
B. Lack of fusion D. Slag Inclusion

4. This welding imperfection is the groove formation at the weld toe,

reducing the cross-sectional thickness of the base metal. The result is
the weakened weld and workpiece.
A. Undercut C. Porosity
B. Slag Inclusion D. Weld Crack

5. The trapped gases create a bubble-filled weld that becomes weak and
can with time collapse.
A. Porosity C. Undercut
B. Slag Inclusion D. Weld Crack

What I Have Learned

Fill in the Blank

___________ exceeding the project criteria are thoroughly removed; however,

the removal of excess ___________ should be minimized to minimize local
stresses. The determination of ___________ excavation sizes for repair is one of
the more difficult evaluations in line installation engineering. This subject has
attracted much ___________ because of personnel safety and the __________ of
the pipeline parting or buckling on the ramp during excavation.

What I Can Do

Instruction: Enumerate the causes and preventions of welding process.

Lack of or incomplete penetration
Main causes: Preventive measures:
____________________________ _____________________________
____________________________ _____________________________
____________________________ _____________________________

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 Assessment

I have learned that ________________________________________

I have realized that ________________________________________

I will apply ________________________________________________

Additional Activities

Identification:

Instruction: Identify the Pictures below manifesting typical imperfections.

1. _____________

2. _____________

3. _____________

4. _____________

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 5. _____________

Answer Key

What I Know What’s In

1. Lack of or incomplete penetration 1. D
2. Lack of Fusion 2. C
3. Porosity 3. B
4. Slag Inclusion 4. A
5. Undercut

What’s More Fill in the blank

1. B 1. Defects
2. D 2. Material
3. A 3. Safe Weld
4. A 4. Attention
5. A 5. Risk

Additional Activities

1. Small bevel angle

2. Incomplete root fusion
3. Thick root face
4. Failure to remove sufficient metal in a double - sided weld
5. Misplaced weld

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References
• https://www.twi-global.com/technical-knowledge/job-knowledge/weld-defects
• https://doi.org/10.1016/B978-0-12-386888-6.00032-8Get rights and content

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 For inquiries or feedback, please write or call:

Department of Education – Schools Division of Negros Oriental

Kagawasan, Avenue, Daro, Dumaguete City, Negros Oriental

Tel #: (035) 225 2376 / 541 1117

Email Address: [email protected]
Website: lrmds.depednodis.net