Grade

11

TVL-IA
SHIELDED METAL ARC WELDING
NCI

QUARTER II – Module 6-Week 6

WELD CARBON STEELPLATE USING

SMAW

1
 Fit up Weld Materials
9-12FW a-1
Quarter II Week 6

Objectives
1 .Perform tack welding.
2. Check gap and alignment.
3. Set up welding positioner.

PREPARED BY:

WILMER J. DIRECTO
SHS-TEACHER

INTRODUCTION

This unit covers the skills, knowledge and attitudes in fitting up welding materials.

Welding is among the most basic metal-joining techniques that date back to the 19th century. Any metallic
construction is merely complete without the welding process. Welding is a metal fabrication process that
uses extremely high temperatures to fuse parts. Filler metal is incorporated to create a strong bond
between the base metal parts.
As simple as it is, welding is a crucial process which if done wrongly, results in dire consequences. These
repercussions range from having weak welding joints to coming down of the whole construction; therefore,
leading to property damage, injuries, and even loss of life.
Redoing a build-up is a frustrating experience that you should avoid at all costs. Quality over anything else is
critical for any weld.
Various welding techniques exist, including gas metal arc welding (GMAW) and shielded metal arc welding
(SMAW). Other terms you are likely to come across in the welding field are spot welding and tack welding.
These are just other welding methods, whose only difference is the technicality applied.
What is Tack Welding?
Using Tack Welds in the Fabrication Process
Risks of Defective Tack Welding
Conclusion
What is Tack Welding?
Tack welding is quite a common term among most welders. Tack welds are weld fixtures that are
temporarily put in place to hold two metals together in the proper location as you apply the final weld.
They are typically small welds spaced out from each other that help you work on your final weld without
worrying over the misalignment of the structure’s parts.
However, tack welds are different from temporary welds in that the former join part of a weldment
while the latter joins the components of a weldment. Tack welds primarily hold edges together. This
welding procedure allows for easy disassembly and re-welding if the final weld is misaligned.
Welding rules state that the same welding procedure must apply for both tack welding and the final welding.
For instance, if you use clamping approach to hold components together in the final welding, this also
applies to tack welding.
Have you ever noticed how the smallest of details result in the most hazardous problems? Similarly, tack
welds, if incorrectly made, may propagate cracks and deficiencies to the final weld. The scientific definition

2
of a tack weld does not define its size or length. However, a desirable tack weld should be relatively small
sized.

Rational
The process of fitting and tack welding metal components is a vital step in the assembly, welding and
finishing of fabricated assemblies.
The well trained welder/fabricator needs to have a solid working knowledge and understanding of the fitting
and tack welding process.
Fitting
The fitting of an assembly is the process of arranging component parts in the correct spatial relationship to
each other.
Fitting can be as simple as creating a basic fillet or groove weld assembly using two pieces of metal, or can
involve using many component parts to create very intricate structures.
No matter the scope of the project being fitted, the process of fitting can play a huge role in the welding and
overall fit and finish of the fabricated assembly.
Listed below are the factors that must be taken into consideration when fitting an assembly that is to be
welded.
Linear and Angular Relationships
Linear and angular relationships describe how the component parts of a fabricated/welded structure are
positioned in relationship to each other.
Linear and angular relationships are generally expressed using a dimension/spatial description and are
communicated using a blueprint or welding procedure specification.
Root Opening
The root opening is the space between two pieces of metal that are used to create a butt or groove weld
joint
The root opening is generally specified on a blueprint or welding procedure specification.
Offset
Offset describes the surface flatness of components that are arranged to create a flat surface.
Offset is often described using the term “flush” to describe the surface relationship of the two adjacent, flat
components.
Where welding is concerned, The American Welding Society D1.1 Structural Steel Code limits the total
amount of allowable offset of welded structures to 10% of the metal thickness up to 1/8” inch.
Tack Welding
The process of using small welds to tack or affix pieces of metal to one another before the final welding is
performed.
Well executed tacks should fit the following criteria:
Large enough to keep the component parts in the correct spatial relationship to each other (Big enough to
do the job)
Small enough to be integrated into the body of the finished weld without being conspicuous (not obvious
after welding)
Spaced correctly. Tack welds should be spaced no more than twenty metal thicknesses apart and should not
exceed on inch in length.
The process of fitting and tacking welded assemblies at a high level of quality is one that comes with
developing an eye for detail and repetition.
In general terms, if the fitting and tack welding process is performed in a sloppy fashion, the process of finish
welding and overall fit and finish of the welded assembly can be greatly affected.
Tack Welding:

Basically, a tack weld is used to maintain stability of your metal as you weld. But it's also a
good technique for avoiding distortion. For example, if you are welding square tube you might
be tempted to tack weld each corner one after the other. And you should. But you first should
put it in a vice, clamp it, or fit it in a jig and then tack weld each opposite corner to keep the
gaps uniform around the tube.

3
Tacked Lap Joints:

Tack Welded Tee Joint:

Tack Welding Pipe:

Tack welding pipe is a very important technique in pipe welding. And pipe welding can be a very technical craft. We will
do a lengthy tutorial on basic pipe welding shortly:

Using Tack Welds in the Fabrication Process

Tack welds are placed either within the joint or outside the joint. For welds within the joint, in most cases,
the tack weld is melted entirely and becomes part of the final weld. For tack welds outside the joint, you
remove them after making the final weldment. You may also consider having these tack welds remain in
place and joining them to the permanent weldment.
Tack welds within the joint are classified as re-melted or incorporated. When fabricating tack welds within
the joint, place the final weld over the tack weld. Heat applied while applying the final weld melts the tack
weld partially, or in some occasions, completely.
Re-melted tack welds apply the concept that heat passed over the final weld melts the tack weld entirely.
Thus, there’s no evidence that the tack weld initially existed. Submerged arc welding (SAW), is mostly
preferred for electrodes with a larger diameter and subsequent high current levels. Electrogas welding
(EGW), is also another preferred technique for the same as it allows for deep heat penetration, consequently
re-melting the tack welds.
Discontinuities in the tack weld should not be a bother since re-melting gets rid of these discontinuities. Ideal
tack welds should be small in size because smaller tack welds are smoother to re-melt, unlike their larger
counterparts. Longer tack welds are also preferred as they enable easy re-melting.

4
Contrarily, incorporated tack welds don’t involve re-melting. The tack weld, in this case, is the root pass of
the final weld. The weld size, preheat, and heat input applied should be in accordance with the root pass.
This type of weld should be entirely free from cracks, as there is no provision to correct the same.
Incorporated tack welds are generally more significant and shorter than the re-melted ones to allow for
more effortless fusion. It’s essential to completely weld the spaces between the tack welds before creating
subsequent layers to avoid disruptions that influence the final look of the weld.
Tack welds outside the joint, also known as non-incorporated joints, are considered as any final weld. The
material and welding technique used for these joints should be applicable also for final welds. Permanent
tack welds, just like final welds, should remain in place without any deficiencies whatsoever. These non-
incorporated welds are continuous and should be strong enough to handle even high strain and stress.
Risks of Defective Tack Welding
As mentioned earlier, incorrect tack welding could result in damage to people and property. Tack welding
should, therefore, be free from weld defects, including cracks, arc strikes, slag, or hard spots. As small as
they seem, cracks may cause the failure of the whole structure.
Quality is critical for any tack weld. Tack welding should be performed by certified welders and according to
the recognized qualified procedure to ensure unmatched quality. The tack welding procedure applied should
be similar to that of the final weld.
Also, the tack weld sequence followed should control distortion. Tack welds should be positioned in such a
way to ensure enough weld penetration. The welds must resist shrinkage to prevent overlapping of one
sheet end over the other.
The tack welds must be cleaned thoroughly before moving on to the application of the final weld. Cleaning is
essential to remove weld oxides formed during welding. Also, the ends of each tack weld are ground to
create a more appealing blended look of the weld into the metal.

With the current improvement in technology, most welding techniques are either automatic or semi-
automatic. Manual assistance is, however, necessary to ensure top-tier quality. Tack welding is needed for
any successful welding project.
Tack welding ensures alignment of all assembled components while controlling distortion during welding.
Therefore, not even the smallest of details should be left to chance.
You should keenly follow all due procedures to avoid the occurrence of any risk. Always remember that in
welding, it’s the smallest mistake that creates the most catastrophic hazard.
Root Gap
Root Gap is the point at which the back of a weld intersects with the base metal surfaces. It
determines the weld penetration and fusion to form a rigid joint. It is made by the first root pass
and supported by other passes.

Root gap should not exceed 1/16-in. Fusible metallic backing is also used with this preparation
with a root gap of at least 1/8-in. The single-Vee groove butt joint with root face and without
external backing is also used for two pass welds where plate thickness exceeds 5/8-in.

GROOVE FACE is that surface of a member that is included in the groove.

The ROOT of a joint is that portion of the joint where the members approach each other most closely. The
root of a joint may be a point, a line,or an area when viewed in cross section. A given joint design may have
a ROOT FACE or it may have a ROOT EDGE.

5
Root face is the surface of the groove that is adjacent to the root of the joint. If the root face is of zero
width, it is known as a root edge

The GROOVE RADIUS is the curved portion of the opening at the bottom of the groove near the root of the
joint.
The BEVEL ANGLE is the angle formed special groove joint designs. between the prepared edges of a
member and a plane perpendicular to the surface of the member.
The ROOT OPENING refers to the separation between th e members of the joint.
The GROOVE ANGLE is the included angle of members are closest together the groove between the parts to
be joined. For example, if the edge of each of the two plates to be
The bevel angle, groove angle, and root opening joined were beveled to an angle of 30�, the groove
of any joint will depend upon the thickness of angle would be 60�.

Root penetration and joint penetration in

ROOT PENETRATION refers to the depth that a groove weld extends into the root of the joint.
6
Root penetration is measured on the center line of the root cross section.
JOINT PENETRATION refers to the minimum depth that a groove weld extends from its face into a
joint,exclusive of any excess weld metal that is above the plate surface.
REINFORCEMENT OF WELD is the term used to describe weld metal, on the face of a groove weld, that is in
excess of the metal necessary for the specified weld size.

ALIGNMENT OF PIPE
Alignment is important if a piping system is to be correctly fabricated. Poor alignment may result in welding
difficulties and a system that does not function properly. Welding rings may be employed to assure proper
alignment as well as the correct welding gap. In addition to using welding rings, some simple procedures can
be followed to assist the pipe fitter. Below and on the following page are alignment procedures commonly
used by today’s craftsmen.
PIPE–TO–PIPE
1. Level one length of pipe using spirit level
2. Bring lengths together leaving only small welding gap
3. Place spirit level over both pipes as shown and maneuver un positioned length until both are level
4. Tack weld top and bottom 5. Rotate pipe 90° 6. Repeat procedure.

Introduction to pipe end measurement

Pipes, tubes and ducts come in many shapes and sizes. Despite improvements in manufacturing
methods, it’s rare for a pipe to be made perfectly round . The illustration below shows the commonly
held belief that pipes are these wonderfully smooth and precisely circular-shaped objects.
Unfortunately, this isn’t a reality. In fact, we know that pipes are never round, but more about this
later.

Pipes are never perfectly round

First, let’s look at the terminology used when measuring pipes, explained in the graphic below.

7
Pipe end measurements
Measurements across the end of a pipe are typically taken over 3 dimensions:
Outer diameter (OD)
Inner diameter (ID)
Wall thickness (WT)
The outer diameter of a pipe, often referred to as OD, is the total distance from one outside edge of
a pipe across a continuous axis to the exact opposite outer edge.
The inner diameter, or ID, of a pipe is the measurement from a point on the inside of a pipe to the
other inside edge across the same axis.
Pipe wall thickness, or WT, is the depth of material of the outer substrate of the pipe.
These 3 dimensions are pretty simple to measure, and for many piping applications they’re relatively
unimportant. However, where pipes are to be used in situations where they might carry a product
that is corrosive or located in a place where atmospheric pressure is high, for example, pipe end
dimensions are a much more important consideration.
Why pipe ends need to be measured
Pipelines are generally used to carry substances from one location to another, often over distances
from a location where human access is limited. When pipes are installed to create a pipeline
infrastructure intended to carry hazardous materials or corrosive liquids such as oil.
The shape of pipe ends become crucial to the integrity of pipeline in high stress areas such as steel
catenary risers (SCR’s). These are the pipes that carry oil from the sea bed up to the surface, typically
to a floating production storage and offloading unit (FPSO). For example, when pipes are used in
deepwater installations, the importance of pipe end shape being a close match to the adjoining pipe
can make a huge difference to the welding of a joint. A welded joint that needs approval by a weld
inspector will need to conform to industry guidelines, such as those set by DNVGL .
The importance of pipe alignment
Despite pipe ends being manufactured to specific tolerances, the fact remains that they are never
perfectly round. To the human eye they might appear to be round, or certainly good enough for
connecting to another pipe. But when measured using a tool that will accurately record the wall
thickness all the way around the diameter of the pipe, the truth becomes clear. Imperfections can be
determined when a pipe is rotated , or aligned, to match the next pipe end in the sequence. This type
of alignment is often referred to as pipe fit-up. This is the process where pipes are checked against
one another to achieve a high to low measurement, or ‘hilo’.
How to achieve good pipe fit-up
Limitations of the pipe production process result in variations in the pipe wall thickness. With the
tools to measure pipes from every aspect now available, pipeline engineers can meet project
specifications safe in the knowledge that they have taken the appropriate steps to ensure the best
possible fit-up.
Pipe end measurement technology has evolved from simple calipers to more advanced tools that can
digitally measure pipe end alignment accurately with repeatable, traceable results that will satisfy
the most stringent project requirements. Pipe ends can also be measured using laser tools which will
capture the dimensions of a pipe end in under 12 seconds to create a point cloud of over 2,000
measurements.
These measurements can be read using dedicated software which has been developed to evaluate
then compare multiple pipe end characteristics against one another. Pipe analysis software allows
pipeline engineers to determine the best possible connections for a set of pipes prior to installation.

8
This means that a pipe sequence can be established with guide marks to indicate the alignment of
each pipe in advance of welding, minimising the risk of problems in the firing line.
POST-TEST
Multiple Choice
Directions: Read and analyze the statement carefully. Choose the best answer and write the letter only in
your answer sheet.
1. The point at which the back of a weld intersects with the base
metal surfaces.
a. Root gap b. Root face c. Fitting d. Tack weld
2. Refers to the depth that a groove weld extends into the root
of the joint.
a. Root penetration b. Root Opening c. Root face d. Root gap 3. Is that surface of a member that
is included in the groove.
a. Groove face b. Groove radius
c. Groove angle d. Bevel angle
4. Refers to the minimum depth that a groove weld extends
from its face into a joint, exclusive of any excess weld metal
that is above the plate surface.
a. Root penetration b. Joint penetration
c. Root face d. Root gap
5. Is important if a piping system is to be correctly fabricated.
a. Linear and Angular Relationships b. Rational
c. Fitting d. Alignment
6. Is quite a common term among most welders.
a. Tack Welding b. Rational
c. Fitting d. Root Opening
7. The process of fitting and tack welding metal components
is a vital step in the assembly, welding and finishing of
fabricated assemblies.
a. Tack Welding b. Rational
c. Fitting d. Root Opening
8. The process of arranging component parts in the correct
spatial relationship to each other.
a. Tack Welding b. Rational
c. Fitting d. Root Opening
9. Describe how the component parts of a fabricated/welded
structure are positioned in relationship to each other.
a. Linear and Angular Relationships b. Rational
c. Fitting d. Root Opening
10. The space between two pieces of metal that are used to create a butt or groove weld joint.
a. Linear and Angular Relationships b. Rational
c. Fitting d. Root Opening
REFERENCES:
1. TRAINING REGULATION ,TESDA.
2. https://www.omsmeasure.com/blog/why-measure-pipe-end-dimensions
3. https://www.thefabricator.com/thewelder/article/cuttingweldprep/how-to...