Grade 12

AUTOMOTIVE SERVICING
Module 1: Weld Carbon Steel Plates Using SMAW
Welding Carbon Steel Plates Using SMAW MEE721306

1st Semester, S.Y. 2020-2021

MDM-Sagay College, Inc.

Office: Feliza Bldg., Marañon St. Pob 2, Sagay City
Campus: National Highway, Poblacion 2, Sagay City, Negros Occidental
Tel.# 488-0531/ email: [email protected].

Module 1: Weld Carbon Steel Plates Using SMAW

Welding Carbon Steel Plates Using SMAW
MEE721306

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Lesson 1. Weld carbon steel plates in flat position (1G)
Learning Outcomes: At the end of the lesson, the student shoul be able to:
1. Preparation of base plate
2. Welding carbon steel plate in Flat position

What I know

Read the questions carefully and select the best answer. Write
the letter of your answer on the space provided.

1. It should be adjusted to give the proper type of flame for the particular metal
being welded.
A. Tip
B. Welding torch
C. Care
D. small puddle

2. By raising and lowering the welding flare with a slight circular motion while
progressing forward.
A. small puddle
B. narrow bead
C. tack welds
D. welding torch

3. The puddle and the base plate and rod are melted together.
A. Narrow bead
B. Bead weld
C. Tack weld
D. Welding rod

4. A given size can be carried along the joint.

A. molten puddle
B. Small puddle
C. Molten metal
D. Small metal

5. It should be moved slightly from side to side to obtain good fusion.

A. Narrow bead
B. Welding torch
C. Torch
D. Care

What’s In

Based on this topic what is 1F?

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 What’s New
Weld Carbon Steel Plates In Flat Position (1G)
Preparation of Base Plate. The bevels are to be flame cut on the edges of the
plate before the parts are assembled. The bevel face must be smooth and free of
notches. The groove face and inside and outside plate surface with in 1” (25mm) of
the joint must be mechanically cleaned of slag, rust and mill scale. Cleaning must be
done with a wire brush or grinder down to bright metal.
Flat Position (1G)
1G is a plate in the flat position that is beveled. This position is the most basic
and only covers the welder in that position.

What is It Flat Position Welding Procedures

In order to make satisfactory bead welds on a plate surface, the flare motion, tip
angle, and position of the welding flame above the molten puddle should be carefully
maintained.
The welding torch should be adjusted to give the proper type of flame for the particular
metal being welded.
Narrow bead welds are made by raising and lowering the welding flare with a
slight circular motion while progressing forward.
The tip should form an angle of approximately 45 degrees with the plate
surface. The flame will be pointed in the welding direction.

Flat Position Narrow Bead Weld

To increase the depth of fusion, either increase the angle between the tip and
the plate surface, or decrease the welding speed.
The size of the puddle should not be too large because this will cause the flame
to burn through the plate.
A properly made bead weld, without filler rod, will be slightly below the upper
surface of the plate. A bead weld with filler rod shows a buildup on the surface.

What’s More

Activity 2

Read the questions carefully and write your answer YES or NO on the separate of
paper. (copy and answer)
1. Deposit weld beads on plate?
2. Weld plates in single pass groove joints in flat positions (1F)
3. Weld plates in multiple pass groove joints in flat position

What I Have Learned

A small puddle should be formed on the surface when making a bead weld with
a welding rod. The welding rod is inserted into the puddle and the base plate and rod
are melted together. The torch should be moved slightly from side to side to obtain
good fusion. The size of the bead can be controlled by varying the speed of welding and
the amount of metal deposited from the welding rod.
Several types of joints are used to make butt welds in the flat position.
Tack welds should be used to keep the plates aligned. The lighter sheets should
be spaced to allow for weld metal contraction and thus prevent warpage.
The following table should be used for selecting the number of passes in butt welding
steel plates:

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 Plate thickness, in. Number of passes 1/8 to 1/4 1 1/4 to 5/8 2 5/8 to 7/8
3 7/8 to 1-1/8
The position of the welding rod and torch tip in making a flat position butt joint
is shown in figure 11-13.
The motion of the flame should be controlled so as to melt the sidewalls of the
plates and enough of the welding rod to produce a puddle of the desired size.
By oscillating the torch tip, a molten puddle of a given size can be carried along the
joint. This will ensure both complete penetration and sufficient filler metal to provide
some reinforcement at the weld.
Care should be taken not to overheat the molten puddle. This will result in
burning the metal, porosity, and low strength in the completed weld.
This position is used in the flat welding position. It’s a fillet symbol.
You will see this used when you need to work with filler that has been rotated so it is
level with the ground.
This is also the easiest of all welding positions. This position is also called the
flat fillet position.
In a fillet weld, this joint will have a base plate that’s at an angle and a joint at a
similar angle, so that the joint itself is facing straight upwards, making your weld area
completely flat in between the plates being fused together.

Assessment

Choose your answer in the box and write it in separate of paper.

(COPY AND ANSWER)

Flat Position Narrow Bead Weld small puddle

Flat Position Welding ProceduresFlat Position (1F) Tack weldswelding rodflamecare

1. What should be spaced to allow for weld metal contraction and thus prevent
warpage?
2. What should be formed on the surface when making a bead weld with a welding
rod?
3. Which is also sometimes called the down hand position?
4. What should be taken not to overheat the molten puddle?
5. What should not be too large because this will cause the flame to burn through
the plate?

Lesson 2. WELD CARBON STEEL PLATES IN HORIZONTAL POSITION (2F)

Learning Outcomes: At the end of the lesson, the student shoul be able to:
1. Essentials of welding
2. International welding codes and standards
3. Acceptable weld profiles
4. Weld defects, causes and remedies
5. Welding Procedure Specifications (WPS)
6. Welding techniques and procedures
7. Safe welding practices

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What’s In

Activity 1
Identification: Fill in the blank answer it in separate of paper (copy and answer)

1. The is used widely in agricultural sectors to make repairs.

2. is rotated in such a way that your filler material is horizontal to the
ground, then you will need to use this position.
3. When you weld from this position, your will need to be 45
degrees.
4. When performing this type of weld, the electrode and the plate sides
should form a .
5. It will be difficult to prevent your joint from being uneven and having the
at the bottom of your joint

What’s New

Horizontal Welding (2F)

This is another fillet weld position, but it is used in horizontal welding.
If you are using this position then you will need to use the top side of a horizontal
surface for welding.
The surface will be lying against another vertical surface. When you weld from
this position, your torch’s angle will need to be 45 degrees.
When your filler weld is rotated in such a way that your filler material is
horizontal to the ground, then you will need to use this position.
It’s harder to use because your molten weld pool is going to try to move
downwards and hit the ground. It will be difficult to prevent your joint from being
uneven and having the filler metal pool at the bottom of your joint.
On top of that, your heat will end up moving upward to the top of the joint.
With the metal flowing downward and the heat rising upward, it can be very easy to
mess up this weld.

What is It

You will end up risking burn through at the top of your joint
and having no penetration. You will need to work hard to master your technique if you
want an even and uniform beading on your joint.
Visually, this joint will have a base plate that is lying flat on the ground and the
plate being fused sticking straight up in the air, forming a T. Your weld will be at
about a 45-degree angle, because it will be nestled into that corner.

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 When welding in the 2G or 2F position it is necessary to control the weld
puddle and travel speed to produce a strong weld. The horizontal position is used
widely in agricultural sectors to make repairs.
The steps necessary to perform welds in the 2G or 2F position are: • Secure the
plate in a position for running beads in a straight line from left to right. Use adjustable
locking piers or C-clamps to secure the metal firmly. • When performing this type of
weld, the electrode and the plate sides should form a 90º angle. Lean the electrode
slightly in the direction of the weld area. • Adjust the amperage, travel speed, and arc
length to prevent the weld puddle from running or sagging. • Metal that is over 1/8-
inch-thick should be beveled prior to welding in the horizontal position. If welding
thicker metal, or metal that has been beveled, it is necessary to make more than one
weld pass to enhance the strength of the weld. • A root, filler, and cap pass will be
necessary.

What’s More
Activity 2

Answer the following questions briefly. Compare your response to the model answer
provided. Indicate whether your response is satisfactory or not satisfactory based on
your own judgment.
Satisfactory
Not Satisfactory
1. Performed lecture and demonstration

2. Trainees comprehension on the subject

3. Trainees performance on Weld carbon steel plates in horizontal position (2F)

Assessment

Read the questions carefully and do it an actual performance.

1. Weld capping/ final pass not exceeding allowable tolerances specified by
welding codes/ standards on • height of reinforcement • underfill • porosities •
undercut • cracks • cold laps
2. Uniformity of bead ripples must be in accordance with welding standards
3. Stringer or layered beads deposited in accordance with welding standards
4. Finish weldment visually acceptable in accordance with welding standards
for: • spatters • arc strikes • slag • uniformity of beads

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Competency-Based Learning Materials

SECTOR: METALS AND ENGINEERING

QUALIFICATION TITLE: SHIELDED METAL ARC WELDING NC II

UNIT OF COMPETENCY: WELD CARBON STEEL PLATES & PIPES USING SMAW MODULE TITLE:
WELDING ON CARBON STEEL PLATES & PIPES USING SMAW

MDM-SAGAY COLLEGE INC. National Highway, Brgy Pob.2 Sagay City, Neg. Occ.

SHIELDED METAL ARC WELDING NC II

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Shielded Metal Arc Welding (SMAW) NC II

List of Competencies

No. Unit of Competency

Module Title

Code

1.

Weld Carbon Steel Plates Using SMAW

Welding Carbon Steel Plates Using SMAW MEE721306

2.

Weld Carbon Steel Pipes Using SMAW

Welding Carbon Steel Pipes Using SMAW MEE721306

SHIELDED METAL ARC WELDING NC II

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MODULE CONTENT

Qualification Title : Shielded Metal Arc Welding NC II Unit of Competency : Weld Carbon Steel Plates
Module Title : Preparing Groove Welding on Carbon Steel Plates

Introduction This module covers the skills, knowledge and attitude required in welding carbon steel
plates in different positions such as 1G, 2G, 3G, & 4G using SMAW process.

Learning Outcomes:

Upon completion of this module, the trainee/student must be able to:

LO.1. Weld carbon steel plates in flat position (1G)

LO.2. Weld carbon steel plates in horizontal position (2G)

LO.3. Weld carbon steel plates in vertical position (3G)

LO.4. Weld carbon steel pates in overhead position (4G)

ASSESSMENT CRITERIA:

• Instructions for the preparation of the work activity are communicated and confirmed to ensure clear
understanding. • Tools, and equipment’s needed to perform SMAW process are identified, checked to
ensure they work correctly as intended and are safe to use in accordance with established procedures
• Materials needed for work are obtained in accordance with established procedures • Protective gears
and body coverings should be used to avoid accidents and injuries. Safety should always be observed. •
SMAW process is performed in accordance to the latest edition of Training Regulations (TR),
Competency Based Curriculum and other related articles obtained from the Technical Education and
Skills Development Authority.

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Learning Outcome # 1:

WELD CARBON STEEL PLATES IN FLAT POSITION (1G)

CONTENTS: 1. Preparation of base plate 2. Welding carbon steel plate in Flat position

ASSESSMENT CRITERIA: 1. Root penetration not exceeding allowable tolerances specified by welding
codes/standards on; concavity, convexity, undercut, excess penetration, lack of fusion, burn-through
and cracks. 2. Weld capping/final pass not exceeding allowable tolerances specified by welding
codes/standards on; height of reinforcement, under fill, porosities, undercut, cracks and cold laps. 3.
Uniformity of bead ripples must be in accordance with welding standards. 4. Stringer or layered beads

7
deposited in accordance with welding standards. 5. Finish weldment visually acceptable in accordance
with welding standards on; spatters, arc strikes; slag; uniformity of beads.

CONDITIONS: Students/trainees must be provided with the following: 1. WORKPLACE 2. TOOLS,

ACCESSORIES AND SUPPLIES Welding mask, electrodes, steel brush, clear and dark glass, chipping
hammer, mechanical pliers. 3. EQUIPMENT Welding machine (AC or AC/DC), welding table, portable
grinder, Welding booth, portable oven 4. TRAINING MATERIALS Competency Based Learning Material on
SMAW NCII

ASSESSMENT METHODS: Direct observation Visual examination of plates

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Learning Experiences

Learning Activities Specific Instruction 1. READ INFORMATION SHEET NO. 1.1-1 on LAWS Code After
reading INFORMATION SHEET NO. 1.1-1 proceed to Task Sheet 1.1-1

2. Perform Task Sheet 1.1-1 Weld Carbon Steel Plates In Flat Position

After performing Weld Carbon Steel Plates In Flat Position, Let the trainer evaluate your work.

After the trainer’s evaluation and approval of the plate, you can proceed to the next LO.

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Information Sheet No. 1.1-1

Weld Carbon Steel Plates In Flat Position (1G)

Preparation of Base Plate The bevels are to be flame cut on the edges of the plate before the parts are
assembled. The bevel face must be smooth and free of notches. The groove face and inside and outside

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plate surface with in 1” (25mm) of the joint must be mechanically cleaned of slag, rust and mill scale.
Cleaning must be done with a wire brush or grinder down to bright metal.

Flat Position (1G)

1G is a plate in the flat position that is beveled. This position is the most basic and only covers the
welder in that position

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TASK SHEET 1.1-1 Title: Weld Carbon Steel Plates In Flat Position

(1G) Performance Objective:

Should be able to perform penetration, filling and capping to plates in flat position

Supplies/Materials:

Electrode, welding mask, clear and dark glass, chipping hammer, steel brush, mechanical pli rs

Equipment: Welding machine (AC or AC/DC), welding table, portable grinder, welding booth, portable
oven

Steps/Procedure: 1. Wear PPE 2. Prepare the base metal. 3. Place the base metal in a flat position
4. Turn on the welding machine 5. Perform welding of carbon steel plates in flat position 6. turn off
the welding machine

Assessment Method: 1. Observation 2. Examination of plates

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Performance Criteria Checklist 1.1-1

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CRITERIA

YES NO

1. Deposit weld beads on plate? 2. Weld plates in single pass groove joints in flat positions 3. Weld
plates in multiple pass groove joints in flat position

SELF-CHECK NO. 1.1-1

Is your response is satisfactory?

Direction: Answer the following questions briefly. Compare your response to the model answer
provided. Tick on the box to indicate whether your response is satisfactory or not satisfactory based on
your own judgment.

Satisfactory

Satisfactory

1. Performed lecture and demonstration

2. Trainees comprehension on the subject

3. Trainees performance on Weld carbon steel plates in flat position

As an overall result, is your response satisfactory?

Satisfactory Not Satisfactory

SHIELDED METAL ARC WELDING NC II

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Date Revised:

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Learning Outcome # 2:

WELD CARBON STEEL PLATES IN HORIZONTAL POSITION (2G)

CONTENTS: 1. Preparation of base plate 2. Welding carbon steel plate in Horizontal position
ASSESSMENT CRITERIA: 1. Root penetration not exceeding allowable tolerances specified by welding
codes/standards on; concavity, convexity, undercut, excess penetration, lack of fusion, burn-through
and cracks. 2. Weld capping/final pass not exceeding allowable tolerances specified by welding
codes/standards on; height of reinforcement, under fill, porosities, undercut, cracks and cold laps. 3.
Uniformity of bead ripples must be in accordance with welding standards. 4. Stringer or layered beads
deposited in accordance with welding standards. 5. Finish weldment visually acceptable in
accordance with welding standards on; spatters, arc strikes; slag; uniformity of beads.

10
CONDITIONS: Students/trainees must be provided with the following: 1. WORKPLACE 2. TOOLS,
ACCESSORIES AND SUPPLIES Welding mask, electrodes, steel brush, clear and dark glass, chipping
hammer, mechanical pliers. 3. EQUIPMENT Welding machine (AC or AC/DC), welding table, portable
grinder, Welding booth, portable oven 4. TRAINING MATERIALS Competency Based Learning Material on
SMAW NCII

ASSESSMENT METHODS: Direct observation Visual examination of plates

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LEARNING ACTIVITIES

Learning Activities Specific Instruction 1. Read information sheet no. 1.2 on weld carbon steel plates in
horizontal position (2g) After reading INFORMATION SHEET NO. 1.2 proceed to Task Sheet 1.2-1

2. Perform Weld Carbon Steel Plates In Horizontal Position

After performing Weld Carbon Steel Plates In Horizontal Position, Let the trainer evaluate your work.

After the trainer’s evaluation and approval of the plate, you can proceed to the next LO.

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INFORMATION SHEET NO. 1.2-1

Horizontal Welding

When welding in the 2G or 2F position it is necessary to control the weld puddle and travel speed to
produce a strong weld. The horizontal position is used widely in agricultural sectors to make repairs.

11
The steps necessary to perform welds in the 2G or 2F position are: • Secure the plate in a position for
running beads in a straight line from left to right. Use adjustable locking piers or C-clamps to secure the
metal firmly. • When performing this type of weld, the electrode and the plate sides should form a 90º
angle. Lean the electrode slightly in the direction of the weld area. • Adjust the amperage, travel speed,
and arc length to prevent the weld puddle from running or sagging. • Metal that is over 1/8 inch thick
should be beveled prior to welding in the horizontal position. If welding thicker metal, or metal that has
been beveled, it is necessary to make more than one weld pass to enhance the strength of the weld. • A
root, filler, and cap pass will be necessary.

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TASK SHEET 1.2-1 Title: Weld Carbon Steel Plates In Horizontal Position (2G)

Performance Objective:

Should be able to perform penetration, filling and capping to plates in horizontal position

Supplies/Materials: Electrode, welding mask, clear and dark glass, chipping hammer, steel brush,
mechanical pliers Equipment: Welding machine (AC or AC/DC), welding table, portable grinder, welding
booth, portable oven

Steps/Procedure: 1. Wear PPE 2. Prepare the base metal. 3. Place the base metal in a horizontal
position 4. Turn on the welding machine 5. Perform welding of carbon steel plates in horizontal position
6. turn off the welding machine

Assessment Method: 1. demonstration 2. observation

SHIELDED METAL ARC WELDING NC II

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Performance Criteria Checklist 1.2-1

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CRITERIA

YES NO

1. Deposit weld beads on plate? 2. Weld plates in single pass groove joints in horizontal positions 3.
Weld plates in multiple pass groove joints in horizontal position

SELF-CHECK NO. 1.2-1

Is your response is satisfactory?

Direction: Answer the following questions briefly. Compare your response to the model answer
provided. Tick on the box to indicate whether your response is satisfactory or not satisfactory based on
your own judgment.

Satisfactory

Satisfactory

1. Performed lecture and demonstration

2. Trainees comprehension on the subject

3. Trainees performance on Weld carbon steel plates in horizontal position

As an overall result, is your response satisfactory?

Satisfactory Not Satisfactory

SHIELDED METAL ARC WELDING NC II

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Date Revised:

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Learning Outcome # 3:

WELD CARBON STEEL PLATES IN VERTICAL POSITION (3G)

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CONTENTS: 1. Preparation of base plate 2. Welding carbon steel plate in Vertical position

ASSESSMENT CRITERIA: 1. Root penetration not exceeding allowable tolerances specified by welding
codes/standards on; concavity, convexity, undercut, excess penetration, lack of fusion, burn-through
and cracks. 2. Weld capping/final pass not exceeding allowable tolerances specified by welding
codes/standards on; height of reinforcement, under fill, porosities, undercut, cracks and cold laps. 3.
Uniformity of bead ripples must be in accordance with welding standards. 4. Stringer or layered beads
deposited in accordance with welding standards. 5. Finish weldment visually acceptable in
accordance with welding standards on; spatters, arc strikes; slag; uniformity of beads.

CONDITIONS: Students/trainees must be provided with the following: 1. WORKPLACE 2. TOOLS,

ACCESSORIES AND SUPPLIES Welding mask, electrodes, steel brush, clear and dark glass, chipping
hammer, mechanical pliers. EQUIPMENT Welding machine (AC or AC/DC), welding table, portable
grinder, Welding booth, portable oven 4. 4. TRAINING MATERIALS Competency Based Learning Material
on SMAW NCII

ASSESSMENT METHODS: Direct observation Visual examination of plates

SHIELDED METAL ARC WELDING NC II

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Date Revised:

Issued by:

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LEARNING ACTIVITIES

Learning Activities Specific Instruction 1. Read information sheet no. 1.3-1 on weld carbon steel plates in
vertical position (3g) After reading INFORMATION SHEET NO. 1.3-1 proceed to Task Sheet 1.3-1

2. Perform Weld Carbon Steel Plates In Vertical Position

After performing Weld Carbon Steel Plates In Vertical Position, Let the trainer evaluate your work.

After the trainer’s evaluation and approval of the plate, you can proceed to the next LO.

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INFORMATION SHEET NO. 1.3-1

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

When welding “vertical up”, position the electrode 85º to the plate in the path of the weld. Begin at the
bottom of the plate and work up.

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Use the same procedures if the electrode sticks or burns through the metal.

As you become better at welding in the 3G and 3F positions, begin work on thicker metals. Experiment
and increase the amperage accordingly. When welding thick plate, use one or more side-to-side
electrode movements.

As with fillet welds, “vertical up” and “vertical down” welds will need more than one pass. A root pass
should be made, along with a filler and cap pass.

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TASK SHEET 1.3-1 Title: Weld Carbon Steel Plates In Vertical Position (3G)

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Performance Objective: Should be able to perform penetration, filling and capping to plates in vertical
position

Supplies/Materials: Electrode, welding mask, clear and dark glass, chipping hammer, steel brush,
mechanical pliers Equipment: Welding machine (AC or AC/DC), welding table, portable grinder, welding
booth, portable oven

Steps/Procedure: 1. Wear PPE 2. Prepare the base metal. 3. Place the base metal in a vertical position
4. Turn on the welding machine 5. Perform welding of carbon steel plates in vertical position 6. turn off
the welding machine

Assessment Method: 1. demonstration 2. observation

SHIELDED METAL ARC WELDING NC II

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Date Revised:

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Performance Criteria Checklist 1.3-1

CRITERIA

YES NO

1. deposit weld beads on plate? 2. weld plates in single pass groove joints in vertical positions 3. weld
plates in multiple pass groove joints in vertical position

SELF-CHECK NO. 1.3-1

Is your response is satisfactory?

Direction: Answer the following questions briefly. Compare your response to the model answer
provided. Tick on the box to indicate whether your response is satisfactory or not satisfactory based on
your own judgment.

Satisfactory

Satisfactory

1. Performed lecture and demonstration

2. Trainees comprehension on the subject

3. Trainees performance on Weld carbon steel plates in flat position

As an overall result, is your response satisfactory?

Satisfactory Not Satisfactory

16
SHIELDED METAL ARC WELDING NC II

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Date Revised:

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Learning Outcome # 4:

WELD CARBON STEEL PLATES IN OVERHEAD POSITION (4G)

CONTENTS: 1. Preparation of base plate 2. Welding carbon steel plate in Vertical position

ASSESSMENT CRITERIA: 1. Root penetration not exceeding allowable tolerances specified by welding
codes/standards on; concavity, convexity, undercut, excess penetration, lack of fusion, burn-through
and cracks. 2. Weld capping/final pass not exceeding allowable tolerances specified by welding
codes/standards on; height of reinforcement, under fill, porosities, undercut, cracks and cold laps. 3.
Uniformity of bead ripples must be in accordance with welding standards. 4. Stringer or layered beads
deposited in accordance with welding standards. 5. Finish weldment visually acceptable in
accordance with welding standards on; spatters, arc strikes; slag; uniformity of beads.

CONDITIONS: Students/trainees must be provided with the following: 1. WORKPLACE 2. TOOLS,

ACCESSORIES AND SUPPLIES Welding mask, electrodes, steel brush, clear and dark glass, chipping
hammer, mechanical pliers. 3. 3. EQUIPMENT Welding machine (AC or AC/DC), welding table, portable
grinder, Welding booth, portable oven 4. 4. TRAINING MATERIALS Competency Based Learning Material
on SMAW NCII

ASSESSMENT METHODS: Direct observation Visual examination of plates

SHIELDED METAL ARC WELDING NC II

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Date Revised:

Issued by:

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LEARNING ACTIVITIES

Learning Activities Specific Instruction 1. Read information sheet no. 1.4-1 on weld carbon steel plates in
overhead position (4g) After reading INFORMATION SHEET NO. 1.4-1 proceed to Task Sheet 1.4-1

2. Perform Weld Carbon Steel Plates In Overhead Position

After performing Weld Carbon Steel Plates In Overhead Position, Let the trainer evaluate your work.

After the trainer’s evaluation and approval of the plate, you can proceed to the next LO.

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INFORMATION SHEET NO. 1.4

Overhead Welding Welding in the 4G or 4F position is the most difficult of the out-of- position welds.
The major challenge in this type of welding is controlling the weld puddle. The procedures for
performing overhead welds are very similar to the flat position, except that they are far more difficult.
It is necessary to pay special attention to the weld puddle and travel speed. You must maintain a short
arc as well. The steps in overhead welding are: Secure the metal overhead with the use of an
adjustable locking pliers or C-clamps. Find a position that is comfortable for you before starting to weld.
Welding in the 4G or 4F position is much more difficult if the welder is uncomfortable from the start.
Adjust the amperage setting and travel speed. The amperage should be set at approximately the same
setting as needed during vertical welding (3). Be certain to maintain a very short arc length throughout
the entire process. Weld with a short arc and use a moderately fast rate of travel to prevent sagging
and undercutting.

A weaving pattern is recommended for use on heavier metals. This motion must be faster than weaves
used for other position welds. Three passes will be needed to complete this weld properly.

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TASK SHEET 1.4-1 Title: Weld Carbon Steel Plates In Overhead Position (4G)

Performance Objective: Should be able to perform penetration, filling and capping to plates in overhead
position

Supplies/Materials: Electrode, welding mask, clear and dark glass, chipping hammer, steel brush,
mechanical pliers Equipment: Welding machine (AC or AC/DC), welding table, portable grinder, welding
booth, portable oven

Steps/Procedure: 1. Wear PPE 2. Prepare the base metal. 3. Place the base metal in a flat position 4.
Turn on the welding machine 5. Perform welding of carbon steel plates in overhead position 6. turn off
the welding machine

Assessment Method: 1. demonstration 2. observation

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Performance Criteria Checklist 1.4-1

CRITERIA

YES NO

1. Deposit weld beads on plate? 2. Weld plates in single pass groove joints in overhead positions 3.
Weld plates in multiple pass groove joints in overhead position

SELF-CHECK NO. 1.4-1

Is your response is satisfactory?

Direction: Answer the following questions briefly. Compare your response to the model answer
provided. Tick on the box to indicate whether your response is satisfactory or not satisfactory based on
your own judgment.

Satisfactory

Satisfactory

1. Performed lecture and demonstration

2. Trainees comprehension on the subject

3. Trainees performance on Weld carbon steel plates in overhead position

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As an overall result, is your response satisfactory?

Satisfactory Not Satisfactory

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MODULE CONTENT

Qualification Title : Shielded Metal Arc Welding NC II Unit of Competency : Weld Carbon Steel Pipes
Module Title : Preparing Groove Welding on Carbon Steel Pipes

Introduction This module covers the skills, knowledge and attitude required in welding carbon steel
plates in different positions such as 2G, 5G, 6G, using SMAW process.

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Learning Outcomes:

Upon completion of this module, the trainee/student must be able to:

LO.1. Weld carbon steel pipes in horizontal position (2G)

LO.2. Weld carbon steel pipes in Fixed pipe horizontal position (5G)

LO.3. Weld carbon steel pipes in fixed pipe, inclined at 45 position (6G)

ASSESSMENT CRITERIA:

• Instructions for the preparation of the work activity are communicated and confirmed to ensure clear
understanding. • Tools, and equipment’s needed to perform SMAW process are identified, checked to
ensure they work correctly as intended and are safe to use in accordance with established procedures
• Materials needed for work are obtained in accordance with established procedures • Protective gears
and body coverings should be used to avoid accidents and injuries. Safety should always be observed. •
SMAW process is performed in accordance to the latest edition of Training Regulations (TR),
Competency Based Curriculum and other related articles obta ned from the Technical Education and
Skills Development Authority.

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Learning Outcome # 1:

WELD CARBON STEEL PIPE IN HORIZONTAL POSITION (2G)

CONTENTS: 3. Essentials of welding 4. International welding codes and standards 5. Acceptable weld
profiles 6. Weld defects, causes and remedies 7. Welding Procedure Specifications (WPS) 8. Welding
techniques and procedures 9. Safe welding practices ASSESSMENT CRITERIA: 1. Root penetration not
exceeding allowable tolerances specified by welding codes/ standards on • concavity • convexity •
undercut • excess penetration • lack of fusion • burn-through • cracks 2. Weld capping/ final pass not
exceeding allowable tolerances specified by welding codes/ standards on • height of reinforcement •
underfill • porosities • undercut • cracks • cold laps • uniformity of bead ripples must be in accordance
with welding standards • stringer or layered beads deposited in accordance with welding standards 3.
Finish weldment visually acceptable in accordance with welding standards for: • spatters • arc strikes •
slag • uniformity of beads

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CONDITIONS: Students/trainees must be provided with the following: The student/trainee must
be provided with the following: 1. Equipment - Welding machine (AC or AC/DC) - Welding table or jig
- Portable grinder - Welding booth - Portable oven 2. Tools/Accessories - Welding mask - Steel brush
- Clear glass - Chipping hammer - Dark glass 3. Supplies/ Materials - Electrodes - Carbon steel plates -
Cutting grinding disk 4. Personal protective equipment - Safety shoes - Apron - Leggings - Safety
goggles - Gloves 5. Training Materials - Arc welding manuals - Welding procedures specifications (WPS)
- Welding standards

ASSESSMENT METHODS: Direct observation Visual examination of plates

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Learning Experiences

Learning Activities Specific Instruction 1. READ INFORMATION SHEET NO. 1.2-1 After reading
INFORMATION SHEET NO. 1.2-1 proceed to Task Sheet 1.2-1 2. Perform Task Sheet 1.2-1 Weld
Carbon Steel Pipes in Horizontal Position (2G) After performing Weld Carbon Pipes Plates in
Horizontal Position, Let the trainor evaluate your work.

After the trainer’s evaluation and approval of the plate, you can proceed to the next LO.

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Information Sheet No. 2.1-1

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Weld Carbon Steel Pipes in Horizontal Position (2G)

Positions for Pipe Welding

Pipe welds are made under many different requirements and in different welding situations. The
welding position is dictated by the job.

In general, the position is fixed, but in some cases can be rolled for flat-position work. Positions and
procedures for welding pipe are outlined below.

Pipe Inclined Fixed (45 degrees + 5 degrees) and Not Rotated During Welding

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Horizontal Pipe Rolled Weld

Align the joint and tack weld or hold in position with steel bridge clamps with the pipe mounted on
suitable rollers. Start welding at point C (figure below) progressing upward to point B. When poi t B is
reached, rotate the pipe clockwise until the stopping point of the weld is at point C and again weld
upward to point B. When the pipe is being rotated, the torch should be held between points B and C
and the pipe rotated past it.

Diagram of Tac Welded Pipe on Rollers

The position of the torch at point A is similar to that for a vertical weld. As point B is approached, the
weld assumes a nearly flat position and the angles of application of the torch and rod are altered slightly
to compensate for this change.

The weld should be stopped just before the root of the starting point so that a small opening remains.
The starting point is then reheated, so that the area surrounding the junction point is at a uniform
temperature. This will ensure a complete fusion of the advancing weld with the starting point.

If the sidewall of the pipe is more than 1/4 in. (0.64 cm) in thickness, a multi-pass weld should be made.

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Horizontal Pipe Fixed Position Weld

After tack welding, the pipe is set up so that the tack welds are oriented approximately as shown below.
After welding has been started, the pipe must not be moved in any direction.

Diagram of Horizontal Pipe Weld with Up hand Method

When welding in the horizontal fixed position, the pipe is welded in four steps as described below.

Starting at the bottom or 6 o’clock position, weld upward to the 3 o’clock position. Starting back at
the bottom, weld upward to the 9 o’clock position. Starting back at the 3 o’clock position, weld to the
top. Starting back at the 9 o’clock position, weld upward to the top overlapping the bead.

When welding downward, the weld is made in two stages. Start at the top (see below) and work down
one side to the bottom, then return to the top and work down the other side to join with the previous
weld at the bottom. The welding downward method is particularly effective with arc welding, since the
higher temperature of the electric arc makes possible the use of greater welding speeds. With arc
welding, the speed is approximately three times that of the upward welding method.

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Horizontal Pipe Weld with Down hand Method

Welding by the backhand method is used for joints in low carbon or low alloy steel piping that can be
rolled or are in a horizontal position. One pass is used for wall thicknesses not exceeding 3/8 in. (0.95
cm), two passes for wall thicknesses 3/8 to 5/8 in. (0.95 to 1.59 cm), three passes for wall thicknesses
5/8 to 7/8 in. (1.59 to 2.22 cm), and four passes for wall thicknesses 7/8 to 1-1/8 in. (2.22 to 2.87
cm).

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TASK SHEET 1.2-1 Title: Weld Carbon Steel Pipes in Horizontal Position

(2G) Performance Objective:

Should be able to perform penetration, filling and capping to plates in Horizontal position

Supplies/Materials:

Electrode, welding mask, clear and dark glass, chipping hammer, steel brush, mechanical pliers

Equipment: Welding machine (AC or AC/DC), welding table, portable grinder, welding boot , portable
oven

Steps/Procedure: 1. Wear PPE 2. Prepare the base metal. 3. Place the base pipe in a Horizontal position
4. Turn on the welding machine 5. Perform welding of carbon steel pipes in horizontal position 6.
turn off the welding machine

Assessment Method: 1. Observation 2. Examination of plates

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Performance Criteria Checklist 1.2-1

CRITERIA

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YES NO

4. Deposit weld beads on pipe? 5. Weld pipes in single pass groove joints in horizontal positions 6.
Weld pipes in multiple pass groove joints in horizontal position

SELF-CHECK NO. 1.2-1

Is your response is satisfactory?

Direction: Answer the following questions briefly. Compare your response to the model answer
provided. Tick on the box to indicate whether your response is satisfactory or not satisfactory based on
your own judgment.

Satisfactory

Satisfactory

4. Performed lecture and demonstration

5. Trainees comprehension on the subject

6. Trainees performance on Weld carbon steel pipes in horizontal position

As an overall result, is your response satisfactory?

Satisfactory Not Satisfactory

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Learning Outcome # 2:

WELD CARBON STEEL PIPE IN FIXED PIPE HORIZONTAL POSITION (5G)

CONTENTS: 1. Essentials of welding 2. International welding codes and standards 3. Acceptable weld
profiles 4. Weld defects, causes and remedies 5. Welding Procedure Specifications (WPS) 6. Welding
techniques and procedures 7. Safe welding practices ASSESSMENT CRITERIA: 1. Root penetration not
exceeding allowable tolerances specified by welding codes/ standards on • concavity • convexity •
undercut • excess penetration • lack of fusion • burn-through • cracks 2. Weld capping/ final pass not
exceeding allowable tolerances specified by welding codes/ standards on • height of reinforcement •
underfill • porosities • undercut • cracks • cold laps 3. Uniformity of bead ripples must be in accordance
with welding standards 4. Stringer or layered beads deposited in accordance with welding standards 5.
Finish weldment visually acceptable in accordance with welding standards for: • spatters • arc strikes •
slag • uniformity of beads

CONDITIONS: Students/trainees must be provided with the following:

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The student/trainee must be provided with the following:

1. Equipment - Welding machine (AC or AC/DC) - Welding table or jig - Portable grinder - Welding
booth - Portable oven 2. Tools/Accessories - Welding mask - Steel brush - Clear glass - Chipping
hammer - Dark glass 3. Supplies/ Materials - Electrodes - Carbon steel plates - Cutting grinding disk
4. Personal protective equipment - Safety shoes - Apron - Leggings - Safety goggles - Gloves 5.
Training Materials - Arc welding manuals - Welding procedures specifications (WPS) - Welding
standards

ASSESSMENT METHODS: Direct observation Visual examination of plates

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Learning Experiences

Learning Activities Specific Instruction 1. READ INFORMATION SHEET NO. 1.2-2 After reading
INFORMATION SHEET NO. 1.2-2 proceed to Task Sheet 1.2-2

2. Perform Task Sheet 1.2-2 Weld Carbon Steel Pipes in horizontal position (5g)

After performing Weld Carbon Pipes Plates in Horizontal Position (5G) , Let the Trainor evaluate your
work.

After the trainer’s evaluation and approval of the plate, you can proceed to the next LO.

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Information Sheet No. 1.2-2

Weld Carbon Steel Pipe in Fixed Pipe Horizontal Position (5G)

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.

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Body positioning for a 5g downhill pipe welding test

Just the fact that pipe is round requires the welder to change body positions as he welds in order to
maintain a favorable electrode angle.

Electrode angle is pretty forgiving on the top portion of a 5g pipe welding test but less forgiving on the
bottom half.

So body positioning is something worth practicing.

And its good to practice it before the hood drops.

Think it thru, go thru the motions several times making sure it all feels comfortable and that you can not
only maintain a good rod angle...but make sure that you can maintain a good line of sight also.

By practicing body positioning with intention, you can create muscle memory.

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5G: the horizontal fixed position. 5G is a lot like 1G in that the pipe is in the horizontal position. The
difference is that the pipe is stationary and not rolling as you weld, which makes it more challenging.

The pipe is horizontal fixed position • Welding downward • Welding upward

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TASK SHEET 1.2-2 Title: Weld carbon steel pipe in horizontal position

(5G) Performance Objective:

Should be able to perform penetration, filling and capping to pipes in Horizontal position (5G)

Supplies/Materials:

Electrode, welding mask, clear and dark glass, chipping hammer, steel brush, mechanical pliers

Equipment: Welding machine (AC or AC/DC), welding table, portable grinder, welding booth, portable
oven

Steps/Procedure: 1. Wear PPE 2. Prepare the base metal. 3. Place the base pipe in a Horizontal position
(5G) 4. Turn on the welding machine 5. Perform welding of carbon steel pipes in horizontal position 6.
turn off the welding machine

Assessment Method: 1. Observation 2. Examination of plates

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Performance Criteria Checklist 1.2-2

CRITERIA

YES NO

7. Deposit weld beads on pipe? 8. Weld pipes in single pass groove joints in horizontal positions (5G)
9. Weld pipes in multiple pass groove joints in horizontal position

(5G) SELF-CHECK NO. 1.2-2

Is your response is satisfactory?

Direction: Answer the following questions briefly. Compare your response to the model answer
provided. Tick on the box to indicate whether your response is satisfactory or not satisfactory based on
your own judgment.

Satisfactory

Satisfactory

7. Performed lecture and demonstration

8. Trainees comprehension on the subject

9. Trainees performance on Weld carbon steel pipes in horizontal position (5G)

As an overall result, is your response satisfactory?

Satisfactory Not Satisfactory

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Learning Outcome # 3:

WELD CARBON STEEL PIPE IN FIXED, PIPE INCLINED AT 45 POSITION (6G)

CONTENTS: 1. Essentials of welding 2. International welding codes and standards 3. Acceptable weld
profiles 4. Weld defects, causes and remedies 5. Welding Procedure Specifications (WPS) 6. Welding
techniques and procedures 7. Safe welding practices ASSESSMENT CRITERIA: 1. Root penetration not
exceeding allowable tolerances specified by welding codes/ standards on • concavity • convexity •
undercut • excess penetration • lack of fusion • burn-through • cracks 2. Weld capping/ final pass not
exceeding allowable tolerances specified by welding codes/ standards on • height of reinforcement •
underfill • porosities • undercut • cracks • cold laps 3. Uniformity of bead ripples must be in accordance
with welding standards 4. Stringer or layered beads deposited in accordance with welding standards 5.
Finish weldment visually acceptable in accordance with welding standards for: • spatters • arc strikes •
slag • uniformity of beads

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 CONDITIONS: Students/trainees must be provided with the following:

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The student/trainee must be provided with the following:

1. Equipment - Welding machine (AC or AC/DC) - Welding table or jig - Portable grinder - Welding
booth - Portable oven 2. Tools/Accessories - Welding mask - Steel brush - Clear glass - Chipping
hammer - Dark glass 3. Supplies/ Materials - Electrodes - Carbon steel plates - Cutting gr nding disk
4. Personal protective equipment - Safety shoes - Apron - Leggings - Safety goggles - Gloves 5.
Training Materials - Arc welding manuals - Welding procedures specifications (WPS) - Welding
standards

ASSESSMENT METHODS: Direct observation Visual examination of plates

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Learning Experiences

Learning Activities Specific Instruction 6. READ INFORMATION SHEET NO. 1.2-3 After reading
INFORMATION SHEET NO. 1.2-3 proceed to Task Sheet 1.2-3 2. Perform Task Sheet 1.2-1 Weld
Carbon Steel Pipes in inclined at 45° position (6g) After performing Weld Carbon Pipes Plates in
Horizontal Position, Let the Trainor evaluate your work.

After the trainer’s evaluation and approval of the plate.

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Information Sheet No. 1.2-2

Weld carbon steel pipe in fixed, pipe inclined at 45° position (6g)

6G: pipe inclined fixed position. 6G is the most difficult of the pipe welding positions because the pipe is
at a forty five degree angle and it is not rolling. And therefore you will need to be able to weld on all
four positions to finish the 6G weld.

The pipe is inclined at a 45° angle

there are a whole crapload of different 6g tests.

the only thing they all have in common is the position.

a 6g position is where the axis of the pipe is on a 45-degree angle.

the reason a 6g position is used is because it tests the welder on his good side as well as the bad...one
side will always seem easier depending on if you are right-handed or left-handed.

some of the more common 6g tests are:

6-inch schedule 80 carbon steel pipe 37 1/2-degree bevels 1/8 gap with 1/8 land. 6010 root, 7018 fill
and cap

6-inch schedule 80 carbon steel pipe 37 1/2-degree bevels 1/8 gap with no land. tig root pass and
second pass, 7018 fill and cap

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TASK SHEET 1.2-3 Title: Weld carbon steel pipe in fixed, pipe inclined at 45° position

(6g) Performance Objective:

Should be able to perform penetration, filling and capping to pipes in inclined at 45° position (6g)

Supplies/Materials:

Electrode, welding mask, clear and dark glass, chipping hammer, steel brush, mechanical pliers

Equipment: Welding machine (AC or AC/DC), welding table, portable grinder, welding booth, portable
oven

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Steps/Procedure: 1. Wear PPE 2. Prepare the base metal. 3. Place the base pipe in inclined at 45°
position (6g) 4. Turn on the welding machine 5. Perform welding of carbon steel pipes in inclined at 45°
position (6g) 6. turn off the welding machine

Assessment Method: 1. Observation 2. Examination of plates

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Performance Criteria Checklist 1.2-3

CRITERIA

YES NO

10. Deposit weld beads on pipe? 11. Weld pipes in single pass groove joints in inclined at 45° position
(6g) 12. Weld pipes in multiple pass groove joints in inclined at 45° position (6g))

SELF-CHECK NO. 1.2-3

Is your response is satisfactory?

Direction: Answer the following questions briefly. Compare your response to the model answer
provided. Tick on the box to indicate whether your response is satisfactory or not satisfactory based on
your own judgment.

Satisfactory

Satisfactory

10. Performed lecture and demonstration

11. Trainees comprehension on the subject

12. Trainees performance on Weld carbon inclined at 45° position (6g)

As an overall result, is your response satisfactory?

Satisfactory Not Satisfactory

38