Department of Education

Region V
Naga City Division
District 1

CAMARINES SUR NATIONAL HIGH SCHOOL

TLE- SMAW 9
LEARNING ACTIVITY SHEET
Quarter 2, Week 3-4

Name: _______________________________________ Grade & Section: __________________

Subject: _______________________________________Date: ___________________________

I. Introductory Concept

Shielded metal arc welding (SMAW) is often referred to as stick welding. The
welding process can use either alternating current (AC) or direct current (DC). This
unit covers the skills, knowledge and attitudes in Laying Out Beads on Carbon
Steel Plates.

II. Learning Competency

 LAYING OUT BEADS ON CARBON STEEL PLATES
CONTENT STANDARDS
The learner demonstrates understanding of basic concepts and
underlying theories in laying out beads on carbon steel plates.
PERFORMANCE STANDARDS
The learner independently demonstrates competency in laying out
beads on carbon steel plates needed for the job.
Reference:
o Technology & Livelihood Education – Grade 9 Industrial
Arts: Shielded Metal Arc Welding - (Laying Out Beads on
Carbon Steel Plates) Learner’s Material First Edition,
2014
o Welding Technology, Second Edition by Gower A.
Kennedy
o Welding Inspection Technology, Education Department,
American welding Society

 Specific Objectives:
1. Identify the methods of striking an arc and factors in selecting
welding electrode
2. Understand the importance of selecting the type of arc welding
electrodes
3. Draw and label the parts of welding process
 INFORMATION / FACT SHEET
LET US STUDY

WORDS TO STUDY

 AC/Alternating Current - kind of electricity which reverses its direction periodically

for 60 cycles current. The current goes in one direction 60 times in the same
seconds, so the cycle changes its direction in 120 times in one second.
 DC/Direct Current - it is a current with a definite or specific sign or symbols
positive and negative.
 DC Generator – direct current and of a none flexible control of arc characteristics
and a stable current.
 AC Transformer – alternating current welding source provide safe welding voltage
 Power Source – an output power of welding machine that supply during welding. It
might supply welding AC or DC power.
 Transformer Rectifier – are designed to provide either AC or DC outputs.
 Electrode – is a metal rod having approximately the same decomposition as the
base metal to be welded.
 Base Metal – is a metal to be welded also known as stock and parent metal.
 Molten Pool – is a location of molten metal produce by heat of welding process.
 Slag – is a nonmetallic by product of welding which attaches itself to the bead.
 Bead - is a ridge of deposited and melted formed at a welded joint.
 Flux - is a liquid or powder used in soldering, brazing or welding to dissolve and
remove oxides that might weaken bond between solder and metal being joined.

INFORMATION SHEET 1.1

Strike an Arc

1. Identify the methods of striking an arc.

2. Prepare the safety gears needed for striking an arc.

Methods of Striking an Arc:

1. Scratching Method. It is done by scratching the electrode to the base

metal like scratching a match. As the electrode scratches the base metal,
an arc will be formed. It is the simplest method for most beginners.
 Figure 2. Scratching Method

2. Tapping Method. It is done by moving the electrode downward until it

just taps the base metal, then bringing the electrode up slightly to form
an arc with the same distances to the diameter of electrode.

Figure 1. Tapping Method

INFORMATION SHEET 1.2

Shielded Metal Arc Welding

Shielded metal arc welding is defined as arc welding with covered electrodes
manually controlled by the welder, without automatic or semi- automatic
replacement of electrode. This process uses a length of flux coated electrode which
provided filler metal and atmospheric shielding.
The electrode is held by the welder in an electrode holder with an insulated
handle. The holder grips the bare end of the electrode for good current transfer.
The welder strikes and draws an arc which melts the base metal forming a
weld pool at the same time. The tip of the electrode melts and metal droplets are
projected into the weld pool.
The chemicals and minerals in coating, melt and decompose to serve as an
alloying element and to form a protecting gas shield around the arc and weld pool.
Furthermore, a slag is formed to cover the deposited weld.
Strike an Arc
SELECTING ELECTRODE
The choice of the right electrode depends on the following factors:

1. Kinds of Base Metal. Electrodes are classified according to the kind of the base
metal for which they are recommended into mild steel low hydrogen, low energy,
cast iron, stainless steel and various non-ferrous electrodes.

2. Types of Welding Equipment. Determine what current is available, as not all

electrodes can be used for both AC or DC current and others are more economical
to use with one type of current than the other. It may also be necessary to check
the open circuit voltage of the welding machine to be used for source electrodes (e.g
basic low hydrogen type) It requires higher open circuit voltage than other for best
performance.

3. Dimension and Design of Parts. Heavy materials of complicated design require

electrodes of high ductility thin plates require low penetration electrodes with
stable arcs at low current values.

4. Joint Preparation and Set up. Deep penetration electrodes are required when
edge is not levelled and fit-up is tight. Mild penetration, thin-coated electrodes are
best when gaps are open.

5. Welding Position. Some electrodes are preferable to others for off-position

welding

6. Specification and Service Condition. Job specifications may indicate class of

electrodes to be used: Otherwise, the service requirements (e.g., desired tensile
strength, ductility, corrosion or abrasion resistance, etc.) should be considered

7. Practicability of Heat Treatment. If shop facilities preclude the employment of

pre-heating or post-heating for critical job, the use of low heat input electrodes is
the only recourse.

8. Cost Limits. The choice of expensive electrodes whose qualities or properties

exceed those normally demanded by the job is economically unwise when less
expensive electrodes, just as suitable quality electrodes and win the risk of the
weldment failing in service or having the job redone at additional cost when
dependable brands are in the market
ELECTRODES
Common ways of classifying electrode (by the covering on the electrode).

1. Bare-Electrode
2. Dusted Electrode
3. Flux-Dipped Electrode
4. Extended Electrodes and Covering

The common electrode width sizes are:

3/32ӯ
1/8ӯ
5/32ӯ
3/16ӯ
7/32ӯ
1/4 ӯ

The common lengths of electrodes are:

14-inches
18-inches

Recommended Current Settings for E-6013 Electrode

Electrode Diameter Ampere Arc Volt

(in mm)

1.58 20-40 17-20

1.98 25-50 17-20

2.38 30-80 17-21

3.17 70-120 18-22

3.96 120-170 18-22

4.76 140-240 20-24

5.55 170-300 21-25

6.35 200-350 22-26

 7.93 250-450 23-27

Table # 1 Current Setting for E-6013 Electrode

ELECTRODE CODING
Electrode End Color Spot Color Group Color
Classification

E-6010 Blue Blue Green

6011 Blue White Green

6012 Blue Brown Silver

6013 Black Green Green

6020 Blue White Green

7010-Al White Yellow Green

7011-Al White Orange Silver

7016 Brown Orange Green

7018 Green Yellow Green

7020-Al Red Brown Green

8015-B1 Green Black

8016-B1 Orange Blue

9016-B3 Brown

10013 Red

10015 Orange

10016 Orange

12016

Table #2 Electrode Coding

AMERICAN WELDING SOCIETY CLASSIFICATION NUMBER OF ELECTRODE

Mild Steel and Low Alloy Electrode AWS-A5.1-89 and A5.1-89. All mild steel
electrode and low alloy electrode are classified with 4- and 5-digits number prefixed
by “E”
First two (or three) digits - tensile strength (Psi) stress relieved as welded.
Third of Fourth - position of welding.

1. All position (flat, horizontal, vertical, overhead position)

Horizontal (flat position only)
 Fourth Digit Type of Coating Welding Current

1 Cellulose potassium AC, DCSP, DCRP

2 Titania sodium AC, DCSP

3 Titania potassium AC, DCSP, DCRP

4 Iron powder titania AC, DCSP, DCRP

5 Low hydrogen sodium DCRP

6 Low hydrogen AC, DCRP

potassium
7 AC, DC
Iron powder oxide
8 AC, DCRP, DCSP
Iron powder, low
0 hydrogen DC reverse polarity

Low hydrogen, iron

powder

Table #3 Classification Number of Electrode

Example:

ELECTRODE CLASSIFICATION

Electrode Type of coating or Capable of Type of Current

Classification covering producing
Number satisfactory weld in
position

E-45 series-minimum tensile strength of deposited metal in non-stress relived

condition 45,000 Psi

E-4510 Sul. coated F.V.OH.H not specified

generally

E-4520 Light coated H. fillet F DCSP-electrode

negative

E-60 series- minimum- tensile strength of deposited metal in non-stress relieved

condition 60,000 Psi

-6010 Hi. Cellulose F.V.OH.H use DC reverse

sodium polarity

E-6011 Hi. Cellulose F.V.OH.H use AC. DCRP

 potassium

E-6012 Titania Sodium F.V.OH.H use AC or DCSP

E-6013 Titania Potassium F.V.OH.H use AC or DCSP

E-6015 Lo-hydro sodium F.V.OH.H use DCRP only

E-6030 Hi-iron oxide H. fillet F. use AC. DC both

polarity

E-70 series-minimum strength of deposited metal in stress relieved condition 70,000

Psi

E-7010 Hi. Cellulose F.V.OH.H use DCRP

sodium

E-7011 HI. Cellulose F.V.OH.H use AC. DCSP

potassium

E-7020 i-iron oxide . fillet F. use AC. DCSP

E-7030 Hi-iron oxide F use AC. DC both

polarity

E-80 series-minimum tensile strength of deposited metal in stress relieved condition

80,

E-8010 Hi. Cellulose F.V.OH.H Use DCRP

sodium

E-8011 Hi. Cellulose F.V.OH.H Use AC. DCRP

potassium

E-8015 Lo-hydro sodium F.V.OH.H Use DCRP

E-8020 Hi-iron oxide F.V.OH.H use AC. DC both

polarity

E-8030 Hi-iron oxide H. fillet F use AC. DC both

polarity

Table #4 Electrode Classification

Note: Sod. – Sodium, Pot- potassium, Ox.-oxide

MILD STEEL ELECTRODE

E-6011

Best for all position, deep penetration, x-ray quality, light slag, medium
deposition rate.
SPECIFICATION AWS Class E-6011

USES: For pipe welding, and structural work, shipbuilding and repair joints
required deep penetration galvanized steel, small diameter wire on straight polarity
for sheet metal, and where quality welds and excellent ductility is required.

PROCEDURE: For general use employ AC or DC straight or reverse polarity. For

short arc, stay ahead of the puddle and use slight whipping motion. For to bottom
use no whipping nor weaving technique.

CHARACTERISTICS: This has slight amount of iron powder as an arc stabilizer.

These decrease spatter and make the arc easier to control.

TIP COLOR: Blue

WELDING CURRENT: Both AC and DC (-), striking voltage ( ) 40V
MECHANICAL PROPERTIES: Tensile Strength. (60,000 – 71,000) Psi – pound per
square inch.
CHEMICAL PROCESS C – 0.10 % P – 0.015 %
Mn – 0.45 % S – 0.035 %
Si – 0.20 %

MILD STEEL ELECTRODE

E-6012

All position except vertically downwards, moderate penetration, excellent quality,

and medium slag high deposition rate.

SPECIFICATION AWS Class E-6012

USES: For fabrication of structural work, storage tanks, railroad cars, poor fit up
and for joints not requirement deep penetration.

PROCEDURE: For general use, electrode negative work positive. Use AC or DC

straight polarity. For flat, angle electrode to 10º to 15º from the perpendicular. For
vertical, reduce heat from flat position. From bottom to top use whipping motion.
From top to bottom use fast travel speed staying below the puddle. For overhead we
employ slight whipping motion.

TIP COLOR: White

WELDING POSITION All except vertical down
WELDING CURRENT both AC and DC (-) striking v. ( ) 50V.
MECANICAL Tensile strength – (67,000 – 70,000) psi
PROCESS
CHEMICAL PROCESS C – 0.07 %
P – 0.02 %
Mn – 0.35 %
S – 0.02 %
Si – 0.20 %

APPROVALS American Welding Society

 AWS, ASTM, ASME, Lloyd’s Register od Shipping

MILD STEEL ELECTRODE

E-6013

All position, mild penetration, good quality, heavy slag.

SPECIFICATION AWS Class E-6013

USES: For fabrication of structural work, poor fit up and joint not requiring deep
penetration.

PROCEDURE: For general use. Employ AC or DC straight or reverse polarity. For

flat, electrode angle to 10O - 15O from the perpendicular. Average arc length with
higher heat than E-6011 electrodes. For vertical reduce the heat from flat position.
Starting from the bottom to top, use fast travel speed staying below puddle.

CHARACTERISTICS: A slag shielded type electrode. Its quick solidifying slag and
quiet arc gives an outstanding performance in vertical and overhead welding. T as a
very shallow penetrating arc which suit galvanized steel, and poorly fitted joints
without tendency of burning through. The bead has a smooth and finely ripple
appearance which eliminate post welding. Easy slag.

TIP COLOR: Brown

WELDING POSITION: All position
WELDING CURRENT: -AC or DC (+) striking V ( ) 50V
MECHANICAL PROPERTIES: Tensile strength – (74,100 psi)

LOW HYDROGEN ELECTRODE

E – 7018

Low hydrogen type electrode for mild, low alloy, and problems steels. All-purpose
electrode.

SPECIFICATION AWS Class E-7018

USES: For joining high Sulphur, low alloy high carbon, and cold rolled steel.
Structural fabrications of flanges, angles, channels iron pipes lines, and
shipbuilding, pressure vessels, bridges, hot and cold cast iron welding.

PROCEDURE: Clean weld area, removing all dirt grease, rust. Rounded the sharp
corners. Keep a medium arc length. Keep (1” – 2”) long bead length must not exceed
twice electrode diameter. Cool each bead slightly before proceeding. Keep base
metal at lowest temperature. Chip off slag between passes.
CHARACTERITICS: Electrode a basic coating for build-up work. High deposition
rate because of high efficiency. Procedure a strong, tough and machinable. Can
withstand 260-300 Brinell Hardness.

TIP COLOR: None

WELDING POSITION: All position including vertical down.
WELDING CURRENT: AC or DC (+), striking V ( ) 70V
MECHANICAL PROPERTIES: Tensile strength – (83,000 – 88,500) psi
CHEMICAL PROCESS
C – 0.09 %
P – 0.02 %
Mn – 1.10 % S – 0.02 %
Si – 0.70 %

STAINLESS ELECTRODE
E-308 L-16

Electrode with extremely low carbon for welding steel of A.I.S.I. types 301 302,
304L and 308.

SPECIFICATION AWS CLASS E-308 L-16

PROCEDURE: Clean weld area, Section of 10 gauge or thinner can be square but
weld. Bevel heavier gauges to 60 degrees. For long seam utilize accurate fit up.
Tack of clamp at short intervals to minimize warping. Keep short arc length. In
filling groove, deposit several light beads only. To preheat warpage, we skip or set
back technique. Use fast travel speed because stainless steel expands 50% more
and conduct heat 50% slower than milder steel.

USES: For welding stainless steel of the 18/8 Cr Ni Extra low carbon type Medium
hard overlays on steel requiring complete corrosion resistance. Applicable to
brewery, dairy, chemical, oil refining and food product.

CHARACTERITICS: Electrode with extremely low carbon content which gives the
weld a very high resistance against inters crystalline corrosion. Produce finely
rippled weld which can be polish.

TIP COLOR: Yellow

WELDING POSITION: All position

WELDING CURRENT: AC or DC (+), striking V ( ) 70V

MECHANICAL PROPERTIES: Tensile strength – (78,000 – 81,000) psi

CHEMICAL PROCESS Cr – 0.17 % - 20% Ni – 10% - 12%

 Mn – 1.10 % C – 0.02%

Si – 0.30 % P – 0.02%

S – 0.02%

Welding Flux

1. Relationships of arc, base metal, electrode and flux:

a) Arc stream is created by holding an electrode approximately 1/8" (3 mm)
away from the base metal.
b) The arc stream creates a molten pool or crater that tends to flow away from
the arc and cools of solidify as it moves
c) Flux from the electrode covering forms a slag on the top of the weld to
protect it from contaminants during cooling.

2. How flux covered electrode works

a) flux covered electrode have a core of metal wire with a baked on chemical
covering
b) the wire core melts in the arcs stream and droplets of metal are transferred
across the arc to make the molten puddle and provide the filler metal to fill
the gap or groove between two base metals
c) the flux covering also melts in the arc stream to stabilize the arc to provide a
shield around the arc, to keep it free from atmospheric impurities and to
form slag covering to protect the weld

Welding Lens

Steps in selecting a safe lens shade for shielded metal arc welding

a) Determine the electrodes size and amperage range because this are used
to dictate the lens protection required.
b) Select lens shade according to the lens manufacturer’s selection chart,
but never select less than a # 8 length shade for shielded metal arc
welding.

Note: When you remove your hood after arc welding and you see white
spots or white blotches as after image it means that you are getting much
light through the lens and you should switch to a shade at least at least one
number darker, or check the seal on your lens.

Electrode Amperage Shade #

Size

- 30 to 75 8

1/16 – 5/32 75 – 200 10

3/16 – 1/4 200 – 400 12

5/16 – 3/8 400 + 14

 c) A rule of thumb is that the larger the diameter of the electrodes, the
higher the number required for a lens shade.

OPERATION SHEET 1.1

Procedures in striking an arc:

Objective: The student will perform the striking of an arc using Tapping and
Scratching.

Conditions or situations for the operations:

1. The distance of an arc must be equal to the diameter of electrode

regardless of the method you used in striking an arc.
2. The materials and equipment must be properly checked.

Equipment, Tools and Materials:

Welding machine on its accessories

 Electrode
 Safety gears
 10mm x 50mm x 100mm steel plate
 Chipping hammer
 Steel brush

Procedure:

1. Prepare the 10mm x 50mm x 100mm steel plate

 2. Prepare the safety gears on welding area.
3. Inspect the connections of the welding machines.
4. Set the welding machines to the recommended current setting.
5. Strike the arc either tapping or scratching method.
6. When the spark appears withdraw the electrode quickly and maintain the
proper arc length approximately the same weight as the diameter of
electrode.
7. Maintain the arc for at least 5-7 seconds.

Precautions:

1. Always check the welding machines and its accessories before and after
using them
2. See to it that there are no combustible materials near the welding area.
3. Always wear protective gears.
4. Observe safety measures while working.

Quality Criteria:

1. The height of the arc is maintained not more than diameter of electrode.
The proper distance of an arc must be maintained for at least 5-7 seconds

ACTIVITY TARGET:

To strike and maintain an arc for 30 seconds with an arc length not to
exceed 4mm at an angle of approximately 75°.

MATERIALS/SUPPLIES

1. mild steel plate, 6mm x 75mm x 150mm

2. 2. electrode E6013, 3.2mm. diameter

TOOLS AND EQUIPMENT

1. AC welding machine with accessories

2. chipping hammer
3. steel brush
4. welding helmet/shield
5. welding gloves
6. welding apron

WELDING PROCEDURE
1. Prepare the tools, equipment and materials needed.
2. Set up the welding machine and set the current to 100 amps.
3. Wear protective clothing and equipment.
4. Clamp the bare end of the electrode in the holder.
5. Position your body in such a way that your head will be cleared of the
column of fumes arising from the arc (Fig. 28)
6. Strike the arc by either of the two methods.
6.1 SCRATCHING

6.1.1 Point the electrode downwards at an angle of approximately 75 deg. and the
striking end about 30 mm above the start position on the plate surface

6.1.2 Strike the end of the electrode on the plate surface similar to striking a
match.
6.1.3 When a spark appears, withdraw the electrode quickly and draw an arc of
approximately 6 mm.

6.1.4 Move the electrode to the start position and then reduce the arc length to a
distance equal to the diameter of the electrode.

6.2 TAPPING

6.2.1 Point the electrode downwards at an angle of approximately 75° and the
striking end to about 15 mm above the start position on the plate surface.

6.2.2 Lower the electrode on the plate surface.

6.2.3 When a spark appears, withdraw the electrode quickly to an arc length equal
to its diameter.

NOTE: If the electrode welds to the plate, quickly snap the electrode to one
side.

If the electrode does not release, switch off the welding machine and
detached the electrode with a cold chisel

Well Prepared Metal Preparation

ACTIVITY 1 (20 points)

A. MULTIPLE CHOICE

Directions: Write the letter of the correct answer for each of the following: Write
your answer in a separate sheet.

1. The coating of electrode is sometimes called:

a. Flux
b. Shield
c. Covering
d. All of these

2. The electrode which has no coating is called:

a. Shielded
b. Bare
c. Dusted
d. Dipped

3. The symbol E-6013;60 means

a. Welding Position
b. Tensile Strength
c. Power Supply
d. Flux Coating

4. The third digit in the symbol E-6013; 1 stands for

a. Welding Position
b. Tensile Strength
c. Power Supply
d. Flux Coating

5. The diameter of the electrode to be used in welding operation depends upon

the:

a. Thickness of the Base Metal

b. Welding Position
c. Type of Base Metal
d. None of these

6. What method in striking an arc is recommended for the beginners?

a. Tapping method
b. Scratching method
c. Any of these
d. None of the above

7. In the symbol E-6013; letter “E” stands for:

 a. Electric
b. Energy
c. Electrode
d. None of the above

8. It is done by touching the electrode to the base metal like scratching a

match.

a. Tapping Method
b. Scratching Method
c. All of these
d. None of there

9. It is done by moving the electrode downward until it steps to the base metal
then bringing the electrode up slightly to form an arc.

a. Taping Method
b. Scratching Method
c. All of these

d. None of these

10.What method in striking an arc is recommended for the beginners?

a. Tapping method
b. Scratching method
c. Any of these
d. None of the above

B. ENUMERATION
1. Methods of Tapping (1-2)
2. Factors in selecting welding electrodes (3-10)

ACTIVITY 2 (15 points)

Briefly answer the following questions. Use separate answer sheet (tablet
paper/long bond paper).

1. Why it is important to know the right welding electrode?

2. Why do we need to follow standard operating procedures in striking an
arc?
3. What are the different methods and procedures applied when striking
an arc? Give examples
 ACTIVITY 3- Performance Task (15 points)

Draw and label the parts of Welding Process (SMAW)

III. Scoring Rubric

Criteria 5 4 3 2

Accuracy Drawing of Drawing of Drawing of No evidence

parts are done most parts are some parts
correctly and done correctly are done
are easy to see. and are easy correctly and
to see are easy to
see.

Labeling Drawing has a Drawing of Drawing of No evidence

Parts set of clear, most parts some parts
neat labels. have a set of have a set of
clear, neat clear, neat
labels. labels.

Neatness Exceptionally Neat and Appears No evidence

well draw, neat relatively messy and in
and attractive. attractive. a hurry.

IV. References:

Welding Principles and Application

By Larry Jeffus and Harold Johnson

Welding Technology 2nd Ed.

By Gower A. Kennedy

Technology & Livelihood Education – Grade 9 Industrial Arts: Shielded

Metal Arc Welding - (laying out Beads on Carbon Steel Plate) Learner’s
Material First Edition, 2014

Prepared by:

DARYL R. TESORO
Teacher I, TLE Department
Camarines Sur National High School

Noted:

ALMIRA S. PADUA
HTVI- TLE/TVE Department
Camarines Sur National High School