AUTOMOTIVE BODY REPAIR AND

PAINT WORK

Short Term Training

Based on May 2023, Curriculum Version I

Module Title: Performing Metal Arc and Oxyacetylene Welding

Module code: EIS BRP2 05 1221
Nominal duration: 60Hours
Prepared by: Ministry of Labor and Skill
July 2023
Addis Ababa, Ethiopia

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Acknowledgment

The Ministry of Labor and Skills (MoLS) is grateful for the invaluable technical assistance provided
by the Deutsche Gesellschaft für Internationale Zusammenarbeit (GIZ) GmbH in developing this
short term training Module. This endeavor was made possible through the Ethio-German Sustainable
Training and Education Programme (STEP), a joint initiative with the ministry, commissioned by the
German Federal Ministry for Economic Cooperation and Development (BMZ) and co-financed by
the European Union.

We would also like to thank INTEGRATION GmbH for their financial support, technical guidance,
and facilitation of the workshop to develop this document. We are also grateful to the MoLS experts,
TVET trainers, and esteemed industry practitioners for their time and expertise in Development of
this Training Module.

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Table of Contents

Acknowledgment ........................................................................................................................... 5
Introduction to the Module .......................................................................................................... 6
Unit One: Prepare and assemble welding materials and equipment ...................................... 7
1.1 Prepare equipment and consumables materials ................................................................ 8
1.2 Preparing Materials ........................................................................................................ 11
Self-Check 1.............................................................................................................................. 18
Operation Sheet 1.1 Preparing tools and equipment for work .................................................. 19
LAP Test 1.1 Practical Demonstration ..................................................................................... 20
Unit Two: Perform MAW Welding........................................................................................ 21
2.1 OHS measures ................................................................................................................ 22
2.2 Setting up welding currency ........................................................................................... 25
2.3 Preparing materials......................................................................................................... 25
2.4 Carrying out welding ...................................................................................................... 26
2.5 Cleaning welding seams ................................................................................................. 28
Self-Check 2.............................................................................................................................. 30
Operation Sheet 2.1 Shielded Metal Arc Welding.................................................................... 31
LAP Test 2.1 Practical Demonstration ..................................................................................... 34
Unit Three: Performing Oxyacetylene weld joints ................................................................. 35
3.1 Welding materials in different position .......................................................................... 36
3.2 Interpreting instructions, symbols, and specifications ................................................... 40
Self-Check 3.............................................................................................................................. 42
Operation Sheet 3.1 Attaching Pressure-Reducing Regulators (Oxy-acytelene welding) ....... 43
Operation Sheet 3.2 Connecting Gas Supplies to the Torch (Oxy-acetylene welding) ............ 45
Operation Sheet 3.3 Testing Connections for Leaks (Oxy-acytelene welding) ........................ 47
Operation Sheet 3.4 Obtaining the Correct Operating Pressure (Oxy-acytelene welding) ...... 49
Operation Sheet 3.5 Lighting the Flame (Oxy-acytelene welding) .......................................... 50

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 LAP Test 3.1 Practical Demonstration ..................................................................................... 53
Unit Four: Correct faults and Assure quality .......................................................................... 54
4.1. Identifying weld defects ................................................................................................. 55
4.2. Removing welding defects ............................................................................................. 55
4.3. Inspecting welding joints ............................................................................................... 59
4.4. Fill weld records ............................................................................................................. 60
Operation Sheet 4.1 Visual Inspection of weld defects ............................................................ 62
LAP Test 4.1 Practical Demonstration ..................................................................................... 63
Reference ..................................................................................................................................... 64

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List of Figure

Figure 1: Welding wire ................................................................................................................... 8

Figure 2: Oxyacetylene ................................................................................................................... 9
Figure 3: Filler Rods ..................................................................................................................... 10
Figure 4: Welding machine ........................................................................................................... 13
Figure 5: Apparatus for Gas welding ............................................................................................ 14
Figure 6: Oxygen pressure regulator............................................................................................. 15
Figure 7: Hose protector ............................................................................................................... 16
Figure 8: Blowpipe and nozzle ..................................................................................................... 16
Figure 9: Types torch heads .......................................................................................................... 17
Figure 10: Welding helmet .......................................................................................................... 23
Figure 11: Welding jacket ............................................................................................................ 23
Figure 12: Gloves ......................................................................................................................... 23
Figure 13: Safety glasses .............................................................................................................. 24
Figure 14: Bead weld .................................................................................................................... 27
Figure 15: Butt weld or groove weld ............................................................................................ 27
Figure 16: Fillet weld .................................................................................................................... 28
Figure 17: Plug or slot welds ........................................................................................................ 28
Figure 18: Types of Welding Flames............................................................................................ 37
Figure 19: Flat welding position ................................................................................................... 38
Figure 20: Horizontal welding position ........................................................................................ 38
Figure 21: Vertical welding position ............................................................................................ 38
Figure 22: Overhead welding position .......................................................................................... 39
Figure 23: Welding Symbols ........................................................................................................ 40
Figure 24: Symbolic Representation of Weld ............................................................................... 41
Figure 25: Welding Defects .......................................................................................................... 58

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Introduction to the Module

This module covers the skills, attitudes and knowledge required in Preparing and assembling
welding materials and equipment, Performing MAW welding, Oxyacetylene welding joints and
Correcting faults and Assure quality.

This module covers:

• Preparing and assemble welding materials and equipment

• Performing MAW welding
• Performing Oxyacetylene welding joints
• Correcting faults and Assure quality

Learning Objective of the Module

• Prepare and assemble welding materials and equipment

• Perform MAW welding
• Perform Oxyacetylene welding joints
• Correct faults and Assure quality

Module Instruction
For effective use of this module, trainees are expected to follow the following module
instruction:
1. Read the information written in each unit.
2. Accomplish the Self-checks at the end of each unit.
3. Perform Operation Sheets at the end of units.
4. Do the “LAP test” giver at the end of each unit and
5. Read the identified reference book for Examples and exercise.

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Unit One: Prepare and assemble welding materials and equipment

This unit is developed to provide you the necessary information regarding the following content
coverage and topics:
1.1 Preparing equipment and consumables materials
1.2 Preparing Materials

This unit will also assist you to attain the learning outcomes stated below. Specifically, upon
completion of this learning guide, trainees will be able to:
• Prepare equipment and consumables materials
• Prepare Materials

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 1.1 Prepare equipment and consumables materials
Gas welding: This term relates to a group of welding processes wherein weld is produced by
heating with a gas flame or flames, with or without application of pressure and with or without
the use of filler wire.
The most common gases are oxygen and acetylene, certain fuel gases hydrogen, LPG, Coal gas
etc. are used.
Welding Wire
Welding wire is a metal rod that you first heat with high-intensity heat and then melt into these
seams before using it on your project.

Figure 1: Welding wire

Oxy-acetylene welding
Oxy-acetylene welding is a method of joining metals by heating them to the melting point using
a mixture of oxygen and acetylene gases.
a. Acetylene
Acetylene is a fuel gas which produces a very high temperature flame with the help of oxygen
because it has more amount of carbon (92.3%) than any other fuel gas. Its chemical symbol is C2
H2 and composed of:
- Carbon 92.3% (24 parts)
- Hydrogen 7.7% ( 2 parts)
It is a colourless gas, lighter than air and highly inflammable and burns with a brilliant flame.
Commercial acetylene has pungent odour because of certain impurities. Acetylene absorbs heat
during producing and liberates heat when decomposed.

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There are two type of acetylene generators:
- Water – to – Carbide generators.
- Carbide – to – Water generators.
b. Oxygen
Oxygen is a supporter of combustion. Its chemical symbol is O2. It is a clear, colourless,
odourless and tasteless gas. It is slightly soluble in water. It does not burn itself, but supports
combustion of fuels. It is industrially produced by two methods:
- By air liquefaction.
- By electrolysis of water.
Oxyacetylene
Oxyacetylene gas welding is commonly used to permanently join mild steel. A mixture of
oxygen and acetylene, burns as an intense / focused flame, at approximately 3,500 degrees
centigrade. When the flame comes in contact with steel, it melts the surface forming a molten
pool, allowing welding to take place. Oxyacetylene can also be used for brazing, bronze welding,
forging / shaping metal and cutting.

Figure 2: Oxyacetylene
Selection of the Filler Rod
Selection of the correct filler rod for a particular job is a very important step for successful
welding. Composition of filler metal is chosen with special consideration to the metallurgical

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requirement of welding. A wrong choice due to either ignorance or a false consideration of
economy may lead to costly failures.

It is strongly recommended that filler material confirming to these specifications is used. In

certain rare cases, it may be necessary to use filler rods of composition not covered by these
specifications; in such cases filler rods with well-established performance should be used.
To select a filler rod in respect to the metal to be welded, the filler rod must have the same
composition with respect to the base metal to be welded.
Types of Filler Rods
The following types of filler rods are classified in gas welding:
• Ferrous filler rod
• Non-ferrous filler rod
• Alloy type filler rod for ferrous metals
• Alloy type filler rod for non-ferrous metals
A ferrous type filler rod has a major % of iron.
The ferrous type filler rod contains iron, carbon, silicon, Sulphur and phosphorous.
The alloy type filler rod contains iron, carbon, silicon and any one or many of the elements such
as manganese, nickel, chromium, molybdenum etc.
The non-ferrous filler rod is a filler rod which contains elements of non-ferrous metals. The
composition of non-ferrous type filler rods is similar to any non-ferrous metal such as copper,
aluminum.
A non-ferrous alloy type filler rod contains metal like copper, aluminum, tin etc. along with
zinc, lead, nickel, manganese, silicon, etc.

Figure 3: Filler Rods

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Fluxes
The purpose of the flux is to retard oxidation of the surfaces of the parts being welded, by
generating gaseous shield around the weld zone. The flux also helps to dissolve and remove
oxides and other substances from the work piece and so contributes to the formation of a stronger
joint. The slag developed protects the molten metal puddles of metal against oxidation as it
cools.
1.2 Preparing Materials
1.2.1 Arc welding materials

Arc welding equipment, setup and related tools and accessories are shown in Figure below.
However some common tools of arc welding are shown separately through Figure. Few of the
important components of arc welding setup are described as under.

1. Arc welding power source

Both direct current (DC) and alternating current (AC) are used for electric arc welding, each
having its particular applications. DC welding supply is usually obtained from generators driven
by electric motor or if no electricity is available by internal combustion engines. For AC welding
supply, transformers are predominantly used for almost all Arc-welding where mains electricity
supply is available. They have to step down the usual supply voltage (200-400 volts) to the
normal open circuit welding voltage (50-90 volts). The following factors influence the selection
of a power source:

Type of electrodes to be used and metals to be welded

• Available power source (AC or DC)
• Required output
• Duty cycle
• Efficiency
• Initial costs and running costs
• Available floor space

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• Versatility of equipment

2. Welding cables

Welding cables are required for conduction of current from the power source through the
electrode holder, the arc, the work piece and back to the welding power source. These are
insulated copper or aluminum cables.

3. Electrode holder

Electrode holder is used for holding the electrode manually and conducting current to it. These
are usually matched to the size of the lead, which in turn matched to the amperage output of the
arc welder. Electrode holders are available in sizes that range from 150 to 500 Amps.

4. Welding Electrodes

An electrode is a piece of wire or a rod of a metal or alloy, with or without coatings. An arc is set
up between electrode and work piece. Welding electrodes are classified into following types-

(i) Consumable Electrodes Bare Electrodes

(ii) Coated Electrodes
(iii) Non-consumable Electrodes Carbon or Graphite Electrodes
(iv) Tungsten Electrodes
Consumable electrode is made of different metals and their alloys. The end of this electrode
starts melting when arc is struck between the electrode and work piece. Thus consumable
electrode itself acts as a filler metal. Bare electrodes consist of a metal or alloy wire without any
flux This coating on melting performs many functions like prevention of joint from atmospheric
contamination, arc stabilizers etc. Non-consumable electrodes are made up of high melting point
materials like carbon, pure tungsten or alloy tungsten etc.
Note: In this level we are going to use consumable electrodes usually coated.

5. Hand Screen: - used for protection of eyes and supervision of weld bead.
6. Chipping hammer:- is used to remove the slag by striking.

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7. Wire brush: - is used to clean the surface to be weld.
8. Protective clothing: - Operator wears the protective clothing such as apron to keep away the
exposure of direct heat to the body.
The following figures are used to describe the welding equipments and their configuration

Figure 4: Welding machine

Oxy-acetylene Welding Materials and equipment

Oxygen gas cylinders

The oxygen gas required for gas welding is stored in bottle shaped cylinders. These cylinders are
painted in black colour. Oxygen cylinders can store gas to a capacity of 7m3 with the pressure
ranging between 120 to 150 kg/cm2. Oxygen gas cylinder valves are right hand threaded.
Dissolved acetylene cylinders
The acetylene gas used in gas welding is stored in steel bottle shaped cylinders painted in
maroon colour. The normal storing capacity of storing acetylene in dissolved state is 6m3 with
the pressure ranging between 15-16 kg/cm2.

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 Figure 5: Apparatus for Gas welding
Oxygen pressure regulator
This is used to reduce the oxygen cylinder gas pressure according to the required working
pressure and to control the flow of oxygen at a constant rate to the blowpipe. The threaded
connections are right hand threaded.

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 Figure 6: Oxygen pressure regulator
Acetylene regulator
This is also used to reduce the cylinder gas pressure to the required working pressure and to
control the flow of acetylene gas at a constant rate to the blowpipe. The threaded connections are
left handed. For quickly identifying the acetylene regulator, a groove is cut at the corners of the
nut.
There are two types of regulators
- Single stage regulator
- Double stage regulator
Hose protectors
At the blowpipes end of the rubber hoses hose-protectors are fitted. The hose protectors are in
the shape of a connecting union and have a non-return disc fitted inside to protect from flashback
and backfire during welding.

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 Figure 7: Hose protector
Blowpipe and nozzle
Blowpipes are used to control and mix the oxygen and acetylene gases to the required
proportion.
A set of interchangeable nozzles/ tips of different sizes is available to produces smaller or bigger
flames.

Figure 8: Blowpipe and nozzle

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 Figure 9: Types torch heads

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 Self-Check 1
Part-I: Choose the correct answer
1. ------------is a method of joining metals by heating them to the melting point using a
mixture of oxygen and acetylene gases.
A. Oxy-acetylene welding
B. Soldering
C. Metal Arc Welding
D. All
2. Which of the following is the type of Welding electrodes?
A. Consumable Electrodes Bare Electrodes
B. Coated Electrodes
C. Non-consumable Electrodes Carbon or Graphite Electrodes
D. All

Part-II: Answer the following questions accordingly

1. List at least 5 components of a welding equipment

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 Operation Sheet 1.1 Preparing tools and equipment for work

Instruction:

✓ Safe working area

✓ Properly operated tools and equipment
✓ Appropriate working cloths fit with the body
Purpose: Ensure a Preparation of tools and equipment for welding

Required tools and equipment: Welding machine.

Consumable Materials: Safety poster, first aid kit, waste bin, Leads, or Welding leads, Rod
holder, or stinger
Procedures:

Step 1: Select, fit and use personal protective clothing and/or equipment
Step 2: Inspecting equipment condition for wear;
Step 3 - Visual inspections of important features prior to starting the work.
Step 4: Visual & function tests while the machine is turned on but stationary
Step 5: Maintain work area to meet housekeeping standards
Step 6: Clean tools equipment and machinery
Step 7: Turn tools equipment and machinery in to their storing area

Quality criteria:
Perform all activities to perform Prepare tools and equipment for work in accordance with the
given procedures

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 LAP Test 1.1 Practical Demonstration

Instruction I: Given necessary templates, tools and materials you are required to perform the
following tasks within 1 hour.
Task 1: Preparing tools and equipment for work

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Unit Two: Perform MAW Welding
This unit to provide you the necessary information regarding the following content coverage
and topics:
2.1 OHS measures
2.2 Setting up welding currency
2.3 Carrying out welding
2.4 Cleaning welding seams

This guide will also assist you to attain the learning outcomes stated below. Specifically, upon
completion of this learning guide, trainees will be able to:
▪ OHS measures
▪ Set up welding currency
▪ Carry out welding
▪ Clean welding seams

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 2.1 OHS measures
Accidents have a far-reaching effect, not only on the victim, but on the victim’s family and
society in general. More importantly accident can cause serious injury, temporary or permanent
or even death.

Safety Recommendations for Arc Welding

The beginner in the field of arc welding must go through and become familiar with these general
safety recommendations which are given as under.
1. The body or the frame of the welding machine shall be efficiently earthed. Pipe lines
containing gases or inflammable liquids or conduits carrying electrical conductors shall
not be used for a ground return circuit All earth connections shall be mechanically strong
and electrically adequate for the required current.
2. Welding arc in addition to being very is a source of infra-red and ultra-violet light also;
consequently the operator must use either helmet or a hand-shield fitted with a special
filter glass to protect eyes.
3. Excess ultra-violet light can cause an effect similar to sunburn on the skin of the welder..
4. The welder‘s body and clothing are protected from radiation and burns caused by sparks
and flying globules of molten metal with the help of the following:
5. Gloves protect the hands of a welder.
6. Leather or asbestos apron is very useful to protect welder‘s clothes and his trunk and
thighs while seated he is doing welding.
7. For overhead welding, some form of protection for the head is required
8. Leather skull cap or peaked cap will do the needful.
9. Leather jackets and 1ather leggings are also available as clothes for body protection.
10. Welding equipment shall be inspected periodically and maintained in safe working order
at all times.
11. Arc welding machines should be of suitable quality.
12. 12. All parts of welding set shall be suitably enclosed and protected to meet the usual
service conditions

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 Welding Personal Protective equipment (PPE)
Welding Helmet

Welding helmet is a helmet designed to protect your eyes, face, and neck from flash burns,
severe sparks, and ultraviolet and infrared rays. It is also known as a hood.

Figure 10: Welding helmet

Welding Jacket

Welding jackets are made from fire-resistant material designed to protect welders from high heat
and metal splatter emitted during welding.

Figure 11: Welding jacket

Welding gloves

Welding gloves are thick gloves made with heat-resistant linings to protect the welder’s hands
from the high heat.

Figure 12: Gloves

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 Safety glasses
Safety glasses can be worn to protect the welder’s eyes from heat and optical radiation that is
generated when welding. They may be used instead of a helmet for certain types of welding
and/or cutting that doesn’t have severe sparking.

Figure 13: Safety glasses

Potential health & safety hazards signs

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 2.2 Setting up welding currency
The welding current that the commercial welders use in general corresponds to the amount of the
heat that is applied to the part that will effect the weld. The welding current depends on the
material that has to be welded and on its thickness, the welding speed itself, the shield gas.
The aim here is to get welds that have no defects with the right kind of penetration. As a rule the
welders start with 1 amp of the welding current that corresponds to 0.001 inch of the thickness of
the material.
In general, if the material is 0.030 inch thick, the average current of the weld should be around
30 amps. In circular parts there might be a heat building up, which could be compensated with
multiple weld current levels. The number of the welding current that are needed depend mainly
on the welding application and on the welding speed.
2.3 Preparing materials
Safety: The repair welding location or area must be surveyed and all safety considerations
satisfied. This can include the posting of the area required by certain regulations, removal of all
combustible materials from the area, the draining of fuel tanks of construction equipment,
aircraft, boats, trucks, etc. Other precautions include the elimination of toxic materials such as
thick coats of lead paint, plastic coverings of metals, etc.
Cleaning: The immediate work area must be clean from all contaminants and this includes
removal of dirt, grease, oil, rust, paint, plastic coverings, etc., from the surface of the parts being
welded. The method of cleaning depends on the material to be removed and the location of the
work piece.
Setting the work piece

Once the selected work piece is prepared and cleaned, the next step is to tap the pieces to be
joined after slightly striking electric arc on the way to checking whether the right amperage is
set. Moreover, the tapped pieces should be positioned and clamped to a system of fixture.
Generally the following should be considered while setting the work piece.
• Set the job in a flat position on the welding table
• Ensure there is good electrical contact between the job and the welding table.

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 2.4 Carrying out welding
Welding is a very common operation in many industries and workplaces. It is defined as “a metal
joining process wherein coalescence is produced by heating to suitable temperature with or
without the use of filler metal”. There is a variety of welding processes that are used in different
working conditions.
Metal joining methods
The origin of welding is probably to be traced to the shaping of metals. In industry every worker
is working for changing the shape of metals by different methods and machines. Welding is a
metal joining method. The following methods are used for joining metals:
(i) Soldering
This joint is made on thin metals using solder as a joining medium. The melting point of solder is
less than the metals to be joined. The joint can be opened by heating upto the solder melting
temperature (below 400°C).
(ii) Brazing
The joint is similar to soldering but has more strength. The joining medium used is brass, which
has a higher melting temperature than solder. The joint can also be opened by heating upto the
melting point of brass (850-950°C).
(iii) Welding
A metal joining method in which the joining edges are heated and fused together with or without
filler metal to form a permanent (homogeneous) bond is known as welding.
Advantages of welding
Welding is superior to other metal joining methods because it:
• Is a permanent pressure tight joint
• Occupies less space
• Gives more economy of material
• Has less weight
• Withstands high temperature and pressure equal to joined material
• Can be done quickly
• Gives no colour change to joints.
• It is the strongest joint and any type of metal of any thickness can be joined.
Types of welds used for automotive body
To get different welding joints the following types of weld are used:

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 1. Bead weld
2. Groove or butt weld
3. Fillet weld
4. Plug or slot weld
Bead weld
Bead weld is a type of weld composed of one or more stringer or weave beads deposited on an
unbroken surface to obtain the desired properties and dimensions

Figure 14: Bead weld

Butt weld or groove weld
Butt weld or groove weld is a weld made in the groove between two members to be joined as
butt joint. Groove welds are also done on T fillet joints if the plate thickness is more than 12mm.

Figure 15: Butt weld or groove weld

Fillet welds
Fillet weld is a weld, having a triangular cross-section, joining two surfaces at right
angle to each other such as:
• Lap joint
• Tee joint
• Corner joint

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 Figure 16: Fillet weld
Plug or slot welds
Plug or slot welds are welds used to join two over-lapping pieces of metal by welding through
circular holes or slots. These welds are often used in the place of rivets.

Figure 17: Plug or slot welds

2.5 Cleaning welding seams
Cleaning is necessary before welding, during welding and is usually essential after welding in
order to ensure maximum corrosion resistance. Each welding run must be thoroughly cleaned to
remove slag and spatter before proceeding with the next run. The cleaning method used
(chipping, brushing, grinding) will depend on the welding process, bead shape, etc. but care
should be taken to see that the weld area is not contaminated in the process.

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Any cleaning equipment should be suitable for stainless steel and kept for that purpose. During
welding, a gas purge on the reverse side may be advantageous. After welding, weld spatter, flux,
scale, arc strikes and the overall heat discoloration should be removed.
This can involve grinding and polishing, blasting and brushing with a stainless steel wire brush,
or use of a decaling solution or paste. The preferred procedure is usually dictated by end use.
Grinding and dressing is to be carried out with iron-free brushes, abrasives, etc. and should not
be so heavy as to discolour and overheat the metal. Rubber and resin bonded wheels are
satisfactory. Wheels should be dressed regularly to prevent them becoming loaded thereby
producing objectionable scratches.

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 Self-Check 2
Part-I: Choose the correct answer.
1. A type of weld composed of one or more stringer or weave beads deposited on an unbroken
surface to obtain the desired properties and dimensions
A. Bead weld
B. Fillet weld
C. Groove or butt weld
D. Plug or slot weld
2. A weld, having a triangular cross-section, joining two surfaces at right angle to each other.
A. Groove or butt weld
B. Plug or slot weld
C. Fillet weld
D. Groove or butt weld

Part-II: Answer the following questions accordingly.

1. List the five types of welding joints.

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 Operation Sheet 2.1 Shielded Metal Arc Welding

Instruction:

✓ Safe working area

✓ Properly operated tools and equipment
✓ Appropriate working cloths fit with the body
Purpose: Ensure a correct Shielded Metal Arc Welding

Required tools and equipment: Welding machine.

Consumable Materials: Safety poster, first aid kit, waste bin, Leads, or Welding leads, Rod
holder, or stinger
Precautions:
✓ Wearing proper clothes, eye glass, glove
✓ Make working area hazard free
✓ Read and interpret manual which guide you how to use tools and equipment
Procedure:
Step 1: Gather the tools and materials needed for welding.

Step 2: Set up a safe work area

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Step 3 Prepare the metal to be welded.
Step 4 Attach clamps to hold your metal pieces together, if need.

Step 5 Attach the ground clamp to the larger piece of stock that is being welded.

Step 6 Select the correct rod and amperage range for the work you are attempting.

Step 7 Select Turn on your welding machine.

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 Step 8 Hold the stinger in your dominant hand by the insulated handle, with the rod in a
position so that striking the tip of it against the plate.

Step 9 Select the point where you wish to begin your weld.

Step 10 Strike the electrode against the surface of the metal, pulling it back slightly when
you see an electric arc occur.

Step 11 Practice traveling across the path of your weld with the electrode until you can keep
a consistent arc, moving at a consistent speed, and in line with the path you want to weld.

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 Step 12 Clean your finished weld.

Step 13 Paint your weld with a suitable rust-preventative primer to protect it from corrosion.

Quality criteria:
Perform all activities to perform Shielded Metal Arc Welding in accordance with the given
procedures

LAP Test 2.1 Practical Demonstration

Instruction I: Given necessary templates, tools and materials you are required to perform the
following tasks within 5 hours.
Task 1: Shielded Metal Arc Welding

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Unit Three: Performing Oxyacetylene weld joints
This unit to provide you the necessary information regarding the following content coverage
and topics:
3.1 Welding materials in different position
3.2 Interpreting instructions, symbols, and specifications
This guide will also assist you to attain the learning outcomes stated below. Specifically, upon
completion of this learning guide, trainees will be able to:
• Weld materials in different position
• Interpret instructions, symbols, and specifications

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 3.1 Welding materials in different position
Joint preparation

Joint preparation is a more technical term used in the welding industry to describe how you
prepare metal for welding.
See, when you weld something you are usually welding two pieces of metal together to form a
joint. And unfortunately many welders do very little if any joint preparation. It's very important
because it's crucial to achieving a good weld. If you don't do any joint preparation you will end
up with 'tall' welds (meaning they are sticking up more than they are getting closer to being flush
with both pieces of metal), and on a more serious note you may get poor fusion.
Types of flame:
As we know there are three basic welding flames. These are as follow.
• Natural Flame:
As the name implies, this flame has equal amount of oxygen and gases fuel by the volume. This
flame burns fuel completely and does not produce any chemical effect on metal to be welded. It
is mostly used for welding mild steal, stainless steel, cast iron etc. It produces little smoke. This
flame has two zones. The inner zone has white in color and has temperature about 3100 degree
centigrade and outer zone has blue color and have temperature about 1275 degree centigrade.
• Carburizing Flame:
This flame has excess of fuel gas. This flame chemically reacts with metal and form metal
carbide. Due to this reason, this flame does not used with metal which absorb carbon. It is smoky
and quiet flame. This flame has three regions. The inner zone has white color, the intermediate
zone which is red in color and outer cone has blue color. The inner cone temperature is about
2900 degree centigrade. This flame is used to weld medium carbon steel, nickel etc.
• Oxidizing Flame:
When the amount of acetylene reduces from natural flame or amount of oxygen increases, the
inner cone tend to disappear and the flame obtain is known as oxidizing flame. It is hotter than
natural flame and has clearly defined two zones. The inner zone has very bright white color and
has temperature of about 3300 degree centigrade. The outer flame has blue in color. This flame is
used to weld oxygen free copper alloy like brass, bronze etc.

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 Figure 18: Types of Welding Flames
Welding Positions
There are 4 basic welding positions
Flat welding position: Generally, flat is an easier position to weld in since you’re not fighting
gravity. The weld puddle stays fluid and wets into the joint evenly. As a result, operators can
typically run hotter with higher deposition rates.

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 Figure 19: Flat welding position
Horizontal welding position: the weld axis is roughly horizontal. Welds in the horizontal
position share many similarities with flat position welds.

Figure 20: Horizontal welding position

Vertical welding position: Operators can complete vertical welds in either vertical up (moving
bottom to top in the weld joint) or vertical down (moving top to bottom in the weld joint).
Vertical up is typically more common, especially on thicker materials. You may need to use this
when working on a large weldment that you can't easily move into the flat or horizontal position.

Figure 21: Vertical welding position

Overhead welding position: Overhead welds may be required when you’re working on a fixed
piece of equipment or metal that cannot be moved. Operators may find themselves lying on the

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ground or floor of their shop for overhead welding, so it’s important to find the most comfortable
position with a range of motion.

Figure 22: Overhead welding position

Techniques of Gas Welding:

There are mainly four types of gas welding:

• Leftward or Forward Welding Technique

In this welding technique, welding is initiated from the right side and proceeded to the left. When
this technique is used, the welding torch is held in the right hand and the filler rod in the left
hand.
The tips of the torch make an angle of 60 to 70 degrees, and the filler rods form an angle of 30–
40 ° from the metal plates that are to be welded. This welding technique is used for spotless steel
plates up to 3 mm and bevel plates up to 6 mm.
• Rightward or Backward Welding Technique

In the welding technique on the right, welding is initiated from the left side and progresses to the
right side. When these techniques are used, the welder holds the welding torch in the right hand
and the filler rod in the left hand. The flame of the torch forms an angle of 40–50 degrees, and
the filler rods form an angle of 30–40 degrees with a metal plate that is to be welded.
• Vertical Welding Technique

In the vertical welding technique, welding is initiated from the bottom and moves upwards.
Metal plates to be welded are placed verticals in this technique. Welding torches and filler rods
are given oscillating movement when using this welding technique.
The flame of the flashlight makes an angle of 25–90 degrees, and the filler rods form an angle of
30 degrees with the vertical plate. For welding plates, more than 5 mm thick, this technique
requires two welders.

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 • Linde Welding Technique

Lind welding is used for butt welding of steel pipes. In this technique, more acetylene flame is
used. The two pipes to be welded are split at 70 degrees and welded together with an interval of
nearly 2.5 mm. During this weldings process, the pipes are rotated continuously so that the seam
is only in the horizontal position. In this technique, true welding is used for welding the pipes.
3.2 Interpreting instructions, symbols, and specifications
Welding symbols

Welding Symbols are a graphical way to convey information about a welding joint. Instead of
using an arrow and saying ‘weld here’, a weld symbol carries more useful information that can
be easily understood by the welder, engineer, foreman, supervisor and architect. Hence, Welding
Symbols are widely used in engineering drawings by welders and engineers to convey essential
information like type of the weld, size of the weld, location of the weld and other supplementary
information as well.

Figure 23: Welding Symbols

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Basic Weld Symbol

1. An arrow line
2. A reference line
3. A dashed line
4. A symbol

Figure 24: Symbolic Representation of Weld

Note: Weld symbols on the full reference line relates to welds on the near side of the plate being
welded. Weld symbols on the dashed line relates to weld on the far side of the plate. If the welds
are symmetrical on both sides of the plate the dashed line is omitted. If the dashed line is above
the full line then the symbol for the nearside weld is drawn below the reference line and the
symbol for the far side weld is above the dashed line.

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 Self-Check 3
Part-I: choose the correct answer
1. ______are used on drawings to indicate the type and specifications of the weld.
A. Welding symbols
B. Joining materials
C. Joining
D. All
Part-II: Answer the following question
1. -------------- It is an oxy-acetylene gas welding technique, in which the welding is begun
at the left-hand edge of the welding job and it proceeds towards the right.

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 Operation Sheet 3.1 Attaching Pressure-Reducing Regulators (Oxy-acetylene welding)

Instruction:

✓ Safe working area

✓ Properly operated tools and equipment
✓ Appropriate working cloths fit with the body
Purpose: Attaching Pressure-Reducing Regulators

Required tools and equipment: Oxy-acetylene Welding Equipment

Consumable Materials: Safety poster, first aid kit, waste bin, Goggles and Glasses, Gloves and
Apron, Spark-Lighter, Filler Rod and Flux Material.
Precautions:
✓ Wearing proper clothes, eye glass, glove
✓ Make working area hazard free
✓ Read and interpret manual which guide you how to use tools and equipment

Procedure
Step 1: Fasten oxygen and acetylene cylinders in an upright position.
Step 2: Clean the valve outlet of accumulated dust or dirt
Step 3: Connect the oxygen and acetylene regulators to their cylinders.
Step 4: Tighten the nuts of the regulator connections with a wrench.

Step 5: Rotate the pressure-adjusting screw to the left until it turns freely. Do this for
each regulator.

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 Step 6: Open the oxygen and the acetylene valves very slowly. Make sure you can see the
cylinder-pressure gauges, but don’t stand directly in front of the valves.
Step 7: Leave the wrench on the acetylene valve while it is open.

Quality criteria:
Perform all activities to Attach Pressure-Reducing Regulators in accordance with the given
procedures

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 Operation Sheet 3.2 Connecting Gas Supplies to the Torch (Oxy-acetylene welding)

Instruction:

✓ Safe working area

✓ Properly operated tools and equipment
✓ Appropriate working cloths fit with the body
Purpose: Ensure a correct Connection of Gas Supplies to the Torch

Required tools and equipment: Oxy-acetylene Welding Equipment

Consumable Materials: Safety poster, first aid kit, waste bin, Goggles and Glasses, Gloves and
Apron, Spark-Lighter, Filler Rod and Flux Material.
Precautions:
✓ Wearing proper clothes, eye glass, glove
✓ Make working area hazard free
✓ Read and interpret manual which guide you how to use tools and equipment
Procedure:
Step 1: Use a hose and hose connections specific to welding and cutting.
Step 2: Do not use any oil or grease on the hoses
Step 3: Attach the oxygen hose to the oxygen regulator and to the torch

.
Step 4: Connect the acetylene hose to the acetylene regulator and to the torch.

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 Step 5: Tighten the hose connections with a wrench. Don’t trust your hand strength to
tighten these connections for you.

Quality criteria:
Perform all activities to Connect Gas Supplies to the Torch in accordance with the given
procedures

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 Operation Sheet 3.3 Testing Connections for Leaks (Oxy-acetylene welding)

Instruction:

✓ Safe working area

✓ Properly operated tools and equipment
✓ Appropriate working cloths fit with the body
Purpose: Ensure a correct Testing Connections for Leaks

Required tools and equipment: Oxy-acetylene Welding Equipment

Consumable Materials: Safety poster, first aid kit, waste bin, Goggles and Glasses, Gloves and
Apron, Spark-Lighter, Filler Rod and Flux Material.
Precautions:
✓ Wearing proper clothes, eye glass, glove
✓ Make working area hazard free
✓ Read and interpret manual which guide you how to use tools and equipment

Procedure
Step 1: Close both torch valves.
✓ For the oxygen, turn the pressure-adjusting screw on the regulator until the gauge
reads about 25 psi.
✓ For the acetylene, turn the pressure-adjusting screw on the regulator until the gauge
reads about 10 psi.
Step 2: Apply a leak-test solution with a brush.

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 Step 3: Check the leak-test solution for bubbles.

Step 4: Release all pressure from any system that has a leak.

Quality criteria:
Perform all activities to Test Connections for Leaks in accordance with the given procedures

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 Operation Sheet 3.4 Obtaining the Correct Operating Pressure (Oxy-acytelene welding)

Instruction:

✓ Safe working area

✓ Properly operated tools and equipment
✓ Appropriate working cloths fit with the body
Purpose: Obtaining the Correct Operating Pressure

Required tools and equipment: Oxy-acetylene Welding Equipment

Consumable Materials: Safety poster, first aid kit, waste bin, Goggles and Glasses, Gloves and
Apron, Spark-Lighter, Filler Rod and Flux Material
Precautions:
✓ Wearing proper clothes, eye glass, glove
✓ Make working area hazard free
✓ Read and interpret manual which guide you how to use tools and equipment

Procedure
Step 1: Turn the oxygen regulator pressure-adjusting screw. Slowly do this until you
reach the desired pressure
Step 2: Adjust the acetylene adjuster screw to the desired working pressure. Do not
exceed 15 psi. Close the acetylene valve immediately after you obtain the right pressure.
Step 3: Do not release acetylene or other gasses near sources of ignition. Also, make sure
you are working in a well-ventilated area. It is advisable to keep a fire extinguisher in your
workspace in case there are any explosions or emergencies.
Quality criteria:
Perform all activities to Obtain the Correct Operating Pressure in accordance with the given
procedures.

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 Operation Sheet 3.5 Lighting the Flame (Oxy-acetylene welding)

Instruction:

✓ Safe working area

✓ Properly operated tools and equipment
✓ Appropriate working cloths fit with the body
Purpose: Ensure a correct Flame Light

Required tools and equipment: Oxy-acetylene Welding Equipment

Consumable Materials: Safety poster, first aid kit, waste bin, Goggles and Glasses, Gloves and
Apron, Spark-Lighter, Filler Rod and Flux Material
Precautions:
✓ Wearing proper clothes, eye glass, glove
✓ Make working area hazard free
✓ Read and interpret manual which guide you how to use tools and equipment

Procedure
Step 1: Check the manufacturer’s instructions for the torch before beginning.
Step 2: Open the torch acetylene valve 1/2 turn and light the flame. Use a friction lighter
rather than a match for this step.
Step 3: Reduce the acetylene flow by adjusting the torch acetylene valve.

Step 4: Turn off the torch if there is flashback.

Step 5: Turn up the gas until you get a flame with no soot.

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 Step 6: Once you have the proper amount of acetylene flowing, start adding some oxygen.
This will change the flame color from yellow to blue.

Step 7: As you continue to add oxygen, you'll see three distinct flame cones: a broad,
feathery outer cone; a medium, blue middle cone; and a short, bright inner cone.

Step 8: Add oxygen until the middle cone just disappears into the inner cone. This is a
neutral flame, the only type that's recommended for welding.

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 Step 9: Practice welding.

Step 10: Start by holding the torch at 45 degrees to the metal

Quality criteria:
Perform all activities to Lighting the Flame in accordance with the given procedures

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LAP Test 3.1 Practical Demonstration

Instruction I: Given necessary templates, tools and materials you are required to perform the
following tasks within 10 hours.
Task 1: Attaching Pressure-Reducing Regulators (Oxy-acetylene welding)
Task 2: Connecting Gas Supplies to the Torch (Oxy-acetylene welding)
Task 3: Testing Connections for Leaks (Oxy-acetylene welding)
Task 4: Obtaining the Correct Operating Pressure (Oxy-acetylene welding)
Task 5: Lighting the Flame (Oxy-acetylene welding)

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Unit Four: Correct faults and Assure quality
This unit is to provide you the necessary information regarding the following content coverage
and topics:
4.1 Identifying weld defects
4.2 Removing defects
4.3 Inspecting welding joints
4.4 Filling weld records
This guide will also assist you to attain the learning outcomes stated below. Specifically, upon
completion of this learning guide, trainees will be able to:
• Identify weld defects
• Remove defects
• Inspect welding joints
• Fill weld records

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4.1. Identifying weld defects
A weld defect results from a poor weld, weakening the joint. It is defined as the point beyond the
acceptable tolerance in the welding process.
Imperfections may arise dimensionally, wherein the result is not up to standard. They may also
take place in the form of discontinuity or in material properties. Common causes of welding
defects come from incorrect welding patterns, material selection, skill, or machine settings,
including welding speed, current, and voltage.
Welding Defects

The lack of training to the operator or careless application of welding technologies may cause
discontinuities in welding. In joints obtained by fusion welding, the defects such as porosity, slag
inclusion, solidification cracks etc., are observed and these defects deteriorates the weld quality
and joint properties.

4.2. Removing welding defects

Common weld defects found in welded joints
These defects may result in sudden failures which are unexpected as they give rise to stress
intensities. The common weld defects include
1. Porosity: is the formation of holes in the weld pool resulting from gas bubbles that cannot
escape.

Causes
• It occurs when the electrode is not coated properly.
• Using a longer arc may also increase its chances.
• Increased welding currents.
• Rust or oil on the welding surface.

Remedies
• Cleaning the weld surface.
• Using the correct welding electrode.
• Preheating the metals before welding.
• Proper gas flow rate setting to achieve the right amount of shielding.
• Regularly checking for moisture contamination in the shielding gas cylinder.

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 • Adjustment of welding current and travel speed settings.
2. Lack of fusion: occurs when the welder does not accurately weld the material and the metal
pre solidifies which leads to a gap which is not filled with the molten metal.

Causes
• Occurs because of the low heat input.
• When the weld pool is very large and runs ahead of the arc.
• When the angle of the joint is too low.
• Incorrect electrode and torch angle may also lead to incomplete fusion.
• Unproper bead position.

Remedies
• Increasing the welding current and decreasing the travel speed helps in removing the
chances of incomplete fusion.
• Reducing the deposition rate.
• Increasing the joint angle.
3. Inclusions: If there is any slag in the weld, then it affects the toughness and metal
weldability of the given material. This decreases the structural performance of the weld
material. Slag is formed on the surface of the weld or between the welding turns.

Causes
• Slag is formed if the welding current density is very small, as it does not provide the
required amount of heat for melting the metal surface.
• If the welding speed is too fast then also slag may occur.
• If the edge of the weld surface is not cleaned properly then also slag may form.
• Improper welding angle and travel rate of welding rod.
Remedies
• Increase the current density
• Adjust the welding speed so that the slag and weld pool do not mix with each other.
• Clean the weld edges and remove the slags of previous weld layers
• Have a proper electrode angle and travel rate.
•

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4. Cracking: This is the most unwanted defect of all the other welding defects. Welding cracks
can be present at the surface, inside of the weld material or at the heat affected zones.

Causes
• Poor ductility of the given base metal.
• The presence of residual stress can cause a crack on the weld metal.
• The rigidity of the joint which makes it difficult to expand or contract the metals.
• If there is high content on sulfur and carbon then also the cracks may appear.
• Using hydrogen as a shielding gas while welding ferrous materials.
Remedies
• Using appropriate materials may decrease the chances of crack.
• Preheating the weld and reducing the cooling speed joint helps in reducing crack.
• Reduce the gap between the weld joints by using reasonable weld joints.
• While welding releases the clamping force slowly which increases fill to capacity of
welding material.
5. Undercut: When the base of metal melts away from the weld zone, then a groove is formed
in the shape of a notch, then this type of defect is known as Undercut. It reduces the fatigue
strength of the joint.

Causes
• If the arc voltage is very high then this defect may occur.
• If we use the wrong electrode or if the angle of the electrode is wrong, then also the
defect may form.
• Using a large electrode is also not advisable.
• High electrode speed is also one of the reasons for this defect.

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6. Overlap: When the weld face extends beyond the weld toe, then this defect occurs. In this
condition the weld metal rolls and forms an angle less than 90 degrees.

Causes
• Improper welding technique.
• By using large electrodes this defect may occur.
• High welding current
Remedies
• Using a proper technique for welding.
• Use small electrode.
• Less welding current

Figure 25: Welding Defects

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4.3. Inspecting welding joints
Measurement and inspection of welded joint is an important step in quality control and reliability
of welded constructions. External inspection allows you to detect such external defects such as
undercuts, uncertified craters facing surface cracks, lack of fusion, flows, etc.

Tests must be made to qualify the process(es) and the operators. Inspection usually involves the
examination of completed welds to establish their quality and their confirmation to
specifications. Thus, testing and inspection determines whether or not the quality standards of
materials and workmanship are being met.

In welded joints, the complexity is further increased by the nature of the joint which is far from
homogeneous, metallurgically or chemically. In addition to the base metal, the welded joint
consists of weld metal and a heat-affected-zone. A variety of properties are thus to be expected
throughout the welded joint.

Visual Inspection

It is the most widely used nondestructive testing technique. It is extremely effective and is the
least expensive inspection method. The welding inspector can utilize visual inspection
throughout the entire production cycle of a weldment.
It is an effective quality control method that will ensure procedure conformity and will catch
errors at early stages.
Visual inspection methods can be divided into three sub-group:
Visual examinations prior to welding: drawings, material specifications, edge preparation,
dimensions, cleanliness of the welding joint etc.
Visual examination during welding: welding process, electrode selection, operating conditions,
preheat requirements, welder performance etc.
Visual examinations of the finished weldment: weld size (using weld gauges), defects (surface
cracks, crater cracks, surface porosity, incomplete root penetration, undercut, underfill),
warpage, base metal defects etc.

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4.4. Fill weld records
A Welding Procedure Specification, or WPS, is a document that serves as a guide for the
effective creation of a weld that meets all applicable code requirements and production
standards. Think of a WPS as a recipe for welders. In the same way that a recipe for a cake
details what ingredients and quantities you’ll need, a WPS contains details that are necessary to
create the desired weld. This includes information such as base metal grade, filler metal
classification, amperage range, shielding gas composition, and pre-heat and interpass
temperatures. The idea is that if a group of welders adhere to all the details on a WPS, they
should each be able to produce welds with reasonably similar mechanical properties.

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Self-Check 4

Part-I: Write true for the right statement and false for wrong one.
1. A weld defect results from a poor weld, weakening the joint.
2. Porosity is the formation of holes in the weld pool resulting from gas bubbles that cannot
escape.

Part-II: Answer the following questions accordingly

1. Write at least four Common weld defects found in welded joints

Note: Satisfactory rating – above 75% Unsatisfactory - below 75%

You can ask your trainer for the copy of the correct answers

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 Operation Sheet 4.1 Visual Inspection of weld defects

Instruction:

✓ Safe working area

✓ Properly operated tools and equipment
✓ Appropriate working cloths fit with the body
Purpose: Ensure a correct Visual Inspection of weld defects
Required tools and equipment: Welding machine.
Consumable Materials: Safety poster, first aid kit, waste bin, Leads, or Welding leads, Rod
holder, or stinger
Procedures:

Step 1: Visual examinations prior to welding

Step 2: Visual examination during welding
Step 3 - Visual examinations of the finished weldment

Quality criteria:
Perform all activities to Visual Inspection of weld defects in accordance with the given
procedures

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 LAP Test 4.1 Practical Demonstration

Instruction I: Given necessary templates, tools and materials you are required to perform the
following tasks within 1 hour.
Task 1: Visual Inspection of weld defects

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Reference

1. https://www.teamry an Automotive.com/strategy-based-diagnostics
2. https://www.autoandbrakerepair.com/blog/fuel-system-common-problems.php
3. https://www.uesystems.com/5-ways-poor-lubrication-can-cause-problems/
4. https://www.yourmechanic.com/article/how-to-diagnose-a-cooling-system-problem-by-
tyler-kirkland

5. https://www.autotrader.co.uk/content/advice/what-is-a-pre-delivery-inspection

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 Participants of This Module (Training Material) Preparation
No Name Qualification Educational Region College Mobile E-mail
background number

1 ABAY KEBEDE Msc. Automotive Dire Dawa Ethio- 0910873087 [email protected]

Technology Italy PTC

2 BIRATU DESALEGN Msc. Automotive Oromia Ambo 0913033783 [email protected]

Technology PTC

3 MULUALEM YIMER Msc. Automotive Amhara W/Siheen 0920207415 [email protected]

Technology PTC

4 SHIFERAW SOLOMON Msc. Automotive Addis Yeka Ind 0910050114 [email protected]

Technology Abeba PTC

5 Yonas Teshome Msc Automotive Addis General 0913073033 Yonas 27teshome @gmail.com
Technology Ababa wingate