Cblm-Smaw-Nc Ii

COMPETENCY BASED LEARNING MATERIAL
Sector : METALS AND ENGINEERING
Qualification Title: SMAW NC II
Unit of Competency: WELD CARBON STEEL PIPES USING SMAW
Module Title: : WELDING CARBON STEEL PIPES USING SMAW
EMN TECHNICAL INSTITUTE TRAINING AND ASSESSMENT CENTER

INC.,
Date Developed: Document No.

August 2022 Issued by:
SMAW NC II Date Revised:
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SHIELDED METAL ARC WELDING NC II
List of Competencies
No. Unit of Competency Module Title Code
Core Competencies
1 Weld Carbon Steel Plates Performing Groove Welding on MEE721306
using SMAW Carbon Steel Plates
2 Weld Carbon Steel Pipes Performing Groove Welding on MEE721306
using SMAW Carbon Steel Pipes

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MODULE CONTENT
UNIT OF COMPETENCY: Weld Carbon Steel Pipes using SMAW

MODULE TITLE : Welding Carbon Steel Pipes using SMAW
MODULE DESCRIPTOR: This module covers groove welding on
carbon steel pipe in 2G
NOMINAL DURATION : 60 HRS

LEARNING OUTCOMES:
Upon completion of this module the trainee/student must be able to:
LO1. Weld carbon steel pipes in horizontal position (2G)
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
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 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 strike
 Slag
 Uniformity of beads

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LEARNING OUTCOME SUMMARY
CONTENTS:
 Essentials of welding
 International welding codes and standards
 Acceptable weld profiles
 Weld defects, causes and remedies
 Welding Procedure Specifications (WPS)
 Welding techniques and procedures
 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

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 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
CONDITIONS:
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)
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- Welding standards
Glossary
Terms and Definitions
Bead Denotes the appearance of the finished weld

and describes the neatness of the ripples
formed by the metal while it is in semi-liquid
state.
2G 2 stands for horizontal and G stands for

groove weld.
DCSP The arc welding leads are arranged so that

the electrode is the negative pole and the base
metal is the positive pole.
DCRP In case of DC polarity, current flows only in

one direction; whereas, in case of AC, current
flow direction reverses in every cycle (number
of cycles per second depends on the
frequency pf supply).
Concave Weld Face A weld having a center of its face below the
weld edges.
Concavity Maximum distance from the face of a concave

fillet weld perpendicular to a line joining the
toes.

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Convexity Maximum distance from the face of a convex
fillet weld perpendicular to a line joining the
toes.
Convex Weld Face A weld having a center of its face above the
weld edges.
Fillet Weld A type of weld which has a triangular cross

section area.
Flat Position The axis of the plate and weld is horizontal.
Horizontal Position The axis of the plate is vertical and axis of the
weld is horizontal.
Overhead Position The axis of the plate and weld is both in

horizontal position. Weld is made on the
underside of the joints.
Penetration The distance from the original surface of the

base metal to that point at which fusion
ceases
Profile Geometrical structure of the weld
Root of Weld Part of a weld farthest from the application of

weld heat and/or filler metal.
Stick Welding Other term for SMAW process

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Vertical Position The axis of the plate and weldment is vertical.
WPS Welding Procedure Specification

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Learning Experiences
Learning Outcome No. 1
Weld carbon steel pipes in vertical position (2G)
Learning Activities Special Instructions

1. Read Information Sheet No. If you have some problem on the content of the
2.1-1 Essential Variables of information sheet don’t hesitate to approach
Welding your facilitator.
If you feel that you are now knowledgeable on the
content of the information sheet, you can now
answer self check provided in the module.
2. Answer Compare your answer to the answer key 2.1-1. If
Self-Check No. 2.1-1 you got 100% correct answer in this self-check,
you can now move to the next information sheet.
If not review the information sheet and go over
the self-check again.
2.1-2 International Welding information sheet don’t hesitate to approach
Codes and Standards your facilitator.
answer self-check provided in the module.
4. Answer Self-Check No. 2.1-2 Compare your answer to the answer key 2.1-2. If
you got 100% correct answer in this self-check,
2.1-3 Acceptable Weld Profile information sheet don’t hesitate to approach
your facilitator.
6. Answer Self-Check No. 2.1- Compare your answer to the answer key 2.1-3. If
3 you got 100% correct answer in this self-check,

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2.1-4 Weld Defects Causes and information sheet don’t hesitate to approach
Remedies your facilitator.
8. Answer Self-Check No. 2.1-4 Compare your answer to the answer key 2.1-4. If
you got 100% correct answer in this self-check,
9. Perform Job Sheet No. 2.1-4 Review the content of Job Sheet No. 2.1-4 Weld
Weld Carbon Steel Pipes in 6G Carbon Steel Pipes in 6G Position using SMAW.
Position using SMAW
If you feel that you are now ready, perform weld
carbon steel pipes in 6G position using SMAW.
Refer to marking schedule for acceptance

criteria.
Check your work by comparing to the

performance standard on observation
checklist.
Ask your trainer to demonstrate the process.
If you pass, you can proceed to the next activity.
2.1-5 Welding Procedures and information sheet don’t hesitate to approach
Specifications your facilitator.

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2.1-6 Welding Techniques information sheet don’t hesitate to approach
and Procedure your facilitator.
13. Answer Self Check No. 2.1- Compare your answer to the answer key 2.1-6. If
2.1-7 Safe Welding Practices information sheet don’t hesitate to approach
your facilitator.

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Information Sheet 1.1-1
Essential Variables of SMAW Welding
Learning Objectives:
At the end of the lesson, the trainees are expected to;
1. Explain the essential variables of SMAW Welding.
Welding is a practical skill that requires continual practice and

careful attention to the variables that the welder controls to
improve. The old golden rule “practice makes perfect” applies to
welding in that the more you do, as long as you or someone
evaluates your welds, the better you become.
The term variable as used in this text means something the welder
has to control of either before welding or during welding.
The Five Essential Variables in SMAW (Stick) Welding
1. Current Setting
The welding current or amperage is essential to producing welds with

good appearance and the required strength characteristics. The
welder controls the amperage variable by setting the correct
amperage required on the welding machine prior to welding.
The amperage is set from the recommended ranges according to the

size of the electrode, the type of electrode, and the type of
current (Alternating Current (AC), Direct Current Reverse
Polarity (DCRP), and Direct Current Straight Polarity (DCSP)) to
be used.
Current Ranges
Size E6010/E6011 E7018
3/32” 60 - 90 70 – 100
1/8” 90 – 120 120 – 160
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5/32” 110 - 170 130 – 170
Some electrodes are designed to work best on a given Current and

Polarity, for example an E-6010 should be used with DCEP (direct current
electrode positive).
Some electrodes are designed to work best on DCEN while others

allow a selection of Current to be used.
Illustration below gives an idea of the evaluation process.
A B C
A – Amperage correct
B – Amperage too low
C – Amperage too high
2. Length of Arc
The arc is the term used to describe the distance from the tip of the
electrode to the base metal and can be varied from lightly touching the metal
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at an angle sufficient to maintain an arc to a distance far enough from the
base metal to extinguish the arc.
The welding machines used in SMAW are known as Constant Current

Welding Machines which means that the current stays relatively constant
through changes in the voltage. The machine increases the voltage as the
arc length is increased to maintain current flow at the amperage level set on
the machine. If the voltage is increased too much the arc may become
unstable and result in a poor quality weld.
The correct arc length may vary according to the type and size of
electrode and the position of welding.
3. Angle of Electrode
In SMAW process two electrode angles that the welder must have to
control. The first angle is the one formed between the electrode and the
base metal called the work angle. The second angle is the angle of the
electrode is held at relative to the direction of travel called the travel angle.
4. Speed of Travel

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The rate of travel across the joint is controlled by the welder during
welding and greatly affects the appearance and strength characteristics of
the welds
The amount of weld metal deposited (weld deposition rate) and

the travel speed may vary with the type and size of electrode being used. The
correct weld speed will result in a well formed weld bead that shows good
fusion, penetration and a gradual transition of weld metal into the corners of
the joint.
Too fast travel speed will result in stringy weld with poor
strength.
Too slow a speed will result in a heavy weld that has too much
convexity
5. Selection of Electrode
There are a variety of electrodes available for welding a wide range of

metals. The electrode for a given application must be selected
In general the electrode weld metal must be matched to the type and
composition of the base metal being welded. Further some electrodes within
the available scope are designed for specific purposes.
Some of the most widely used Electrodes are those used for welding
carbon Steel.
The following is a brief description of the most commonly used

electrodes for welding Carbon Steel.
The electrodes are classified by a letter and numbering system as

follows:

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The tensile strength is defined as the ability of the weld metal to
withstand forces acting to pull it apart.
The last digit indicates the type of flux or electrode covering and in
turn determines the type of current, penetration and appearance of the
weld.
The following are some commonly used electrodes and their

characteristics.

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Self – Check No. 1.1-1
Essential Variables of SMAW Welding
Multiple Choice:
Direction: Select the best answer and write the letter that corresponds to
your choices on answer sheet.
1. It is defined as the ability of the weld metal to withstand forces

acting to pull it apart.
A. Durability C. Hardness
B. Tensile Strength D. Resistance
2. E 7028 is manipulated in what position?

A. All position C. Flat Vertical Fillets
B. Flat Horizontal Fillets D. All of the above
3. The correct arc length may vary according to

A. Welding Position C. Type of welding machine
C. Type of current D. Kind of base metal
4. What must be matched to the type and composition of the base

metal being welded?
A. current C. amperage
B. welding machine D. electrode weld metal
5. Which electrode is used to weld on flat and horizontal position?

A. E 6010 C. E 7018
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B. E 6013 D. E 6027
Answer Key 1.1-1
Essential Variables of SMAW
1. B
2. B
3. D
4. D
5. D

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Information Sheet No. 1.1-2
International Welding Codes and Standards
Objectives:
1. Identify the different welding codes and standards.

2. Explain the application of the different welding codes and
standards.
Codes and standards help to standardize welding.
Some of the common codes and welding standards.
1. American Welding Society (AWS)
This codes covers the welding requirements for any type of

welded structure made from the commonly used carbon and low-
alloy steels.
The following AWS Standards
AWS D1.1 Structural Welding (Steel)

AWS D1.2 Structural Welding (Aluminum)
AWS D1.3 Structural Welding (Sheet Steel)
AWS D1.4 Structural Welding (Reinforcing Steel)
AWS D1.5 Bridge Welding
AWS D1.6 Structural Welding (Stainless Steel)
AWS D1.7 Structural Welding (Strengthening and
Repair)
AWS D10.11 Root Pass Welding for Pipe
AWS D10.12 Pipe Welding (Mild Steel)
AWS D10.18 Pipe Welding (Stainless Steel)
2. American Society of Mechanical Engineers (ASME) IX
The American Society of Mechanical Engineers (ASME)

Boiler and Pressure Vessel Code (BPVC) covers all aspects of
design and manufacture of boilers and pressure vessels. All
sections contain welding specifications, however most relevant
information is contained in Sections V and IX.

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 ASME BPVC Section V: "Non destructive testing"
 ASME BPVC Section IX: "Welding and Brazing Qualifications"
 ASME B16.25: "Butt-welding ends" (of pipes and piping
components)
3. American Petroleum Institute (API) 1104
This code applies for gas and oil pipeline facilities. When
segments of pipe nipples are used, they shall be supported so
that typical flat, vertical, and overhead welds are produced.

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Multiple Choice:
Direction: Read and analyze the statement carefully. Choose the best
answer and write the letter only in your answer sheet.
1. In what section does the most relevant information is contained in

ASME IX?
A. Section V and IX C. Section V and X
B. Section VI and VII D. Section VII and VIII
2. This codes covers the welding requirements for Structural Welding

(Reinforcing Steel)?
A. AWS D1.1 C. AWS D1.5
B. AWS D1.4 B. AWS D1.2
3. Which of the following welding codes that covers all aspects of

design and manufacturers of boiler sand pressure vessel?
A. AWS C. API
B. ISO D ASME
4. This codes covers the welding requirements for Root Pass Welding
for Pipe?
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A. AWS D10.18 C. AWS D10.11
B. AWS D10.12 D. AWS D1.1
Answer Key 1.1-2
1. A.
2. B
3. D
4. C

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Acceptable Weld Profiles
Objectives:
1. Identify the acceptable weld profiles.
The profile of a completed weld could possibly have considerable

affect for the performance of that weld operating. It is your welding
inspector’s function to distinguish these discontinuities by way of
visual inspection and quite often to evaluate his/her acceptance, or
negativity.
Note: Convexity C of a weld or individual surface bead with dimension

W shall not exceed the value of the following table

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Acceptable Weld Profiles
Multiple Choice:
1. Acceptable convexity of weld reinforcement in groove weld shall not

exceed
A. 3 mm C. 5 mm
B. 4 mm D. 6 mm
2. The maximum root face made in preparing single-V groove is

A. 3/32” C. 1/8”
B. 5/32” D. 1/4"
3. The correct bevel angle in preparing butt joint is

A. 30 deg. C. 50 deg
B. 40 deg. D. 60 deg
4. The correct groove angle in preparing butt joint is

A. 30 deg. C. 50 deg
B. 40 deg. D. 60 deg
5. The appropriate size of tack weld in joining the work piece is

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A. 5 mm C. 15 mm
B. 10 mm D. 20 mm
Answer Key 1.1-3
Welding Codes and Standards
1. B
2. C
3. A
4. D
5. B

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Weld Defects, Causes, and Remedies
Objectives:
1. Identify the different weld defects its causes and remedies.
Weld Defects
A weld should have a good appearance. However, a

defective weld is one that will be strong enough to do the job
and may fail after it is put into used. Weld defects usually
happen when the correct preparation and/or welding
techniques are not used.
General Classification of Weld Defects:
1. Structural Defects – include surface and internal cracks and

defects
Types of Structural Defects:
1.1 Crater Cracks – cracks left at the depression at the end of

the bead

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Cause: Improper termination of the electrode at the end of
the weld
1.2 Longitudinal Cracks – cracks run parallel to the weld bead.

They may be in the bead itself or in the metal
along the edge of the bead.
Causes: a. Wrong electrode

b. Improper joint design
c. Poor edge preparation
d. Poor clamping of the welded joint
1.3 Cross-sectional Crack – cracks across the weld bead.
Causes: a. Wrong electrode

b. Improper joint design
c. Poor edge preparation
d. Poor clamping of the welded joint
1.4 Undercutting – depression at the toe of the weld – the weld

metal is below the level of the base metal.
Causes: a. Faulty electrode manipulation

b. Current too high
c. Travel speed is too slow

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1.5 Slag Inclusion – entrapment of nonmetallic materials such
as cellulose or limestone at the weld and base
metal.
Causes: a. Poor edge preparation

b. Dirty filler metal and parent metal
c. Incorrect use of the different welding
techniques
1.6 Porosity – small gas pockets or holes in the welded metal
Causes: a. Dirty filler metal and parent metal

b. Too short arc length
c. Insufficient puddling time
1.7 Poor Penetration – happens when the joint or root weld

penetration does not meet the weld
requirement for full strength

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1.7.1 Incomplete Penetration

b. Travel speed is too fast
c. Low current setting
1.7.2 Over Penetration

b. Travel speed too slow
c. Too short arc length
d. Current too high
1.8 Incomplete Fusion – when the filler .metal and parent metal
are not completely fused

b. Travel speed is too fast
c. Low current setting

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2. Dimensional Defects – if the joint preparation, weld size, and/or weld
shape differ from the specification
Types of Dimensional Defects:
2.1 Warpage – (also known as bowing or cambering) shrinkage

of the weld bends the metal or pulls the metal
parts out of alignment
Causes: A. Poor joint alignment

B. Current too high
2.2 Angular Distortion or Angular Warpage – when the metal

parts are at an angle to one another and the
shrinkage changes the angle.

B. Current too high
2.3 Longitudinal Shrinkage – distortion along the length of the

weld.

B. Current too high
2.4 Transverse Shrinkage – distortion across the weld

B. Current too high

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Weld Defects, Causes, and Remedies
Multiple Choice:
Direction: Read and analyze the statement carefully. Choose

the best answer and write the letter only in your answer sheet.
1. This weld defects is caused by improper termination of the electrode at

the end of the weld.
A. Crater Cracks C. Cross-sectional Crack
B. Longitudinal Cracks D. Cracks
2. The type of weld defects that is defined as entrapment of nonmetallic

materials such as cellulose or limestone at the weld and base metal.
A. Poor Penetration C. Slag Inclusion
B. Porosities D. Undercut
3. This weld defect is caused by poor joint alignment and too high
current setting.
A. Porosities C. Incomplete Fusion
B. Warpage D. Poor Penetration

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4. What cause undercut?
A Low amperes C. Too long arc
B High amperes D. Poor preparation of work piece
5. Welding distortion, war page and stresses are cause by

A. High temperature C. Intermittent welding
B Strong backs D. Back step welding
Answer Key 1.1-4
Weld Defects, Causes and Remedies
1. A
2. C
3. C
4. B
5. A

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Job Sheet No. 1.1-4
Weld Carbon Steel Pipes in 2G Position using SMAW
Performance Objectives:
Given the necessary supplies, materials, tools and equipment, the
trainee should be able to;
Make multiple pass in carbon steel pipes in 2G position using
SMAW
Supplies/Materials:
2 pcs Carbon Steel Pipes 3/8” T x 6” OD x 4”

6 pcs Electrode E 6011, 3.2 mm Ø
12 pcs Electrode E 7018 3.2mm Ø
1 pc Soapstone
Equipment/Tools:
1 unit SMAW machine with complete accessories

1 unit Portable Electric Grinder
1 set PPE
1 pc Chipping Hammer
1 pc Ball peen Hammer
1 pc Steel Brush
1 pc Spacer Wire
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1 pc Plier/ Tong
Specifications:
A. Joint design and weld symbol
SMAW 2G
B. Electrode E 6011, 3.2 mm Ø for root pass and E 7018, 3.2mm Ø

for cap pass
C. Current: DCRP
D. Position: 6G
E. Technique: Drag and/or Whip Motion
F. Cleaning: Chipping and Brush
G. Testing: Bend Test
Procedures:
A. Check work area to make sure it is free of flammable materials and

well ventilated, and note the location of the nearest fire
extinguisher.
B. Attach ground cable to work table or workpiece.
C. Select correct5 polarity for electrode.
D. Turn On SMAW machine.
E. Put on welding helmet and adjust machine to correct amperage by

running a test bead on scrap metal.
F. Place the pipes on work table positioned so that one is on top of the
other to form a vertical axis with a 1/16” gap wire placed between
the two pipes.

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G. Place a straight edge along the inside of the nipples and align them
vertically.
Straight Edge
Spacer Wire
H. Tack weld the members in place according to the following

procedure:
1. Start between the spread ends of the gap wire and make the
first tack weld.
2. Move 180° opposite the first tack weld, pull the gap wire out
from between the two nipples, use one end of the gap wire to
recheck the gap at that point, then make the second tack.
3. Move 90° in either direction from the second tack weld and
make the third tack weld.
4. Move 180° opposite the third tack weld and make the fourth
tack weld.

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A. Feather all tack welds with a grinder, but be careful not to grind all
the way through the tack weld.
B. Place the nipples so that they are in the position indicated in

specifications
K. Place E 6011 electrode in the electrode holder and adjust to correct

electrode angle
L. Strike an arc on on end of the feathered tacks at 3 o’clock ( or 9

o’clock) and quickly adjust to proper arc length
Caution: Strike the arc only in the weld zone and not on the
finished sides of the pipe.
M. Make a puddle and immediately form a keyhole

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N. Whip the rod slightly forward the keyhole to solidify, than whip the
rod back to deposit more metal n the keyhole.
Note:
Do not deposit filler metals outside the keyhole as you
whip the rod back and forth; always move the rod back to the
center of the keyhole, and keeps electrode arcing in the middle of
the joint and not on the outer portion of the bevel.
O. Weld up to the center of the 12 o’clock tack weld and stop at the
center point of the tack.
P. Restart arc at the center of tack weld at 6 o’clock, form proper keyhole
and weld up to the center of the tack weld at 9 o’clock and stop.
Q. Go back to the tack weld at 6 o’clock, restart arc to tie-in with

previous quarter pass, form proper keyhole and weld up to tack weld
at 3 o’clock and tie-in with first quarter pass.
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R. Go across to tack weld at 9 o’clock, restart arc to tie-in with previous
quarter pass, form proper keyhole and weld up to tack weld at 12
o’clock and tie-in with the first quarter pass.

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S. Chip slag off stringer bead and brush it, or grind the entire stringer
bead with a hand grinder.
T. Inspect the root pass for good fusion and penetration and for defects
such as undercutting on both outside and inside surfaces.
U. Adjust amperage to proper setting for E 7018 electrode.
V. Use the E 7018 electrode, with a weaving technique, lay stringer

beads for remainder of fill-up, and be sure to clean each pass before
starting the next one.
W. Clean fill-up stringer beads thoroughly.
X. Use the E 7018 electrode and with a weaving technique, lay a cap
pass to finish the weld with vertical up welding from 6 to 12 o’clock on
each side.
Y. Clean and inspect cap pass
Z. Have your instructor check your work.
AA. Shut down SMAW machine
BB. Conduct a bend test as outlined in a previous job sheet.
CC. Have your instructor check your bend test
DD. Check in tools and materials and clean up area, or prepare for
next job sheet as directed by your instructors.

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Performance Criteria Checklist
Weld Carbon Steel Pipes in 2G Position using SMAW
PERFORMANCE
Criteria Yes No
1. Bead profile not more than 1 mm in
concavity and convexity as per plan
specifications.
2. Ripple regular in appearance achieved
conforms with WPS.
3. Width of bead conforms to the industry
standards
.
4. Height of bead conforms to the industry
standards
5. Plate squareness conforms to the
acceptance with the industry standards
6. Weld defects conforms to the acceptance
criteria of the industry standards
Marking Table
CRITERIA MARK SUBTRACTED

1. Profile
2. Ripple
3. Width of Bead
4. Height of Bead
5. Plate Squareness
6. Free of Structural Defects
Total Marks Subtracted
Final Points = 30 – Total Marks Subtracted

= 30 - ___________________
Final Points = _______________________

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MARKING SCHEDULE
1. Profile
Subtract 3 marks for each millimeter beyond of the accepted
convexity. (3 mm is the maximum convexity)
2. Ripple
Subtract 3 marks for coarse ripple
3. Width of Bead
Subtract 2 marks for each 10 mm length of bead that is 2 mm
beyond of the accepted width bead.
4. Height of Bead
Subtract 2 marks for each 10 mm length of bead which exceed
the bead height of 3 mm.
5. Plate Squareness
Subtract 2 marks for each 3 degrees of variation on squareness.
6. Free of Structural Defects
Subtract 3 marks for each structural defects appeared in the
weldment

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Welding Procedures and Specifications
Objectives:
1. Interpret welding procedures and specifications.
Welding Procedures and Specifications (WPS) is a document

that describes how welding is to be carried out in production. They are
recommended for all welding operations and many application codes
and standards make them mandatory.
Before any welding can be done on a structure, the procedure

that will be used must first be approved or qualified. Welding
Procedures Specification (WPS) is written to specify welding
requirements for commercial jobs such as bridges, pipelines, or steel
structures. Outlines exactly how each weld is to be made and
generally prepared by engineers.
A welding procedure qualification record shows the properties of

a weld that was made by following the welding procedures
specification is said to be qualified. Once welding procedure
specifications are written and qualified, the WPS can be followed and
welding can begin on the project. Both the WPS and the WPQR must
be kept on file.
Sample
Welding Procedures Specification No: PRACTICE 6-7

Date: _______________
TITLE:
Welding SMAW of plate to plate
SCOPE:

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This procedure is applicable for V-groove plate with a backing
strip within a range of 3/8 “ (10mm) through 3/4" (20 mm)
Welding may be performed in the following positions: 1G, 2G, 3G and
4G
BASE METAL:
The base metal shall conform to AWS specification No. E 6010
or E 6011 root pass and E 7018 for the cover pass from AWS
specification A5.1. This filler metal falls into F-number: F3 and F4 and
A –number: A-1
SHIELDING GAS
The shielding gas or gases shall conform to the following
compositions and purity: N/A
JOINT DESIGN AND TOLERANCES
PREPARATION OF BASE METAL:

The V-groove is to be ground, flame cut, or machined on the deg
of the plate before the parts are assembled. All parts must be cleaned
prior to welding of all contaminants, such as paints, oils, grease, or
primers. Both inside and outside surfaces within 1” (25.4 mm) of the
joint must be mechanically cleaned using a wire brush or grinder.
ELECTRICAL CHARACTERISTICS:
The current shall be AC or DCRP. The base metal shall be on
the work lead or negative side of the line.
PREHEAT:

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The parts must be heated to a temperature higher than 70º F
(21º C) before any welding is started.
BACKING GAS: N/A
WELDING TECHNIQUE:
Tack welds the plates together with the strip. There should be
about a 1/8” (3.2 mm) root gap between the plates. Use the E 6010 or
E 6011 arc welding electrodes to make a root pass to fuse the plates
and backing strip together. Clean the slag from root pass and use
either a hot pass or grinder to remove any trapped slag.
Using E 7018 arc welding electrode, make a series of filler welds

in the groove until the joint is filled.
INTERPASS TEMPERATURE:
The plate should not be heated to a temperature higher than
400º F (205º C) during the welding process. After each weld pass is
completed, allow it to cool, the weldment must not be quenched in
water.
CLEANING:
The slag can be chipped and/or ground off between passes but
can only be chipped off of the cover pass.
INSPECTION:
Visually inspect the weld for uniformity and other
discontinuities. If the weld passes the visual inspection, then it is to
be prepared and guided bend tested according to Guided Bend Test.
Repeat each of the weld until you can pass this test.

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Multiple Choice:

1. What is the process which the parts must be heated to a

temperature higher than 70º F (21º C) before any welding is started?
2. __________ is a document that describes how welding is to be

carried out in production. They are recommended for all welding
operations and many application codes and standards make them
mandatory.
3. A ____________ is a record that shows the properties of a weld that

was made by following the welding procedures specification is said to
be qualified.
4. There should be about a ____________ root gap between the plates.
5. What is the hand tool used for removing slags?

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Answer Key 1.1-5
1. PREHEAT
2. Welding Procedures and Specifications (WPS)
3. Welding Procedure Qualification
4. 1/8” (3.2 mm)
5. Chipping Hammer

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Welding Techniques and Procedures
Objectives:
1. Be aware of the different welding techniques and

procedure for better welding result.
2. Adopt proper welding techniques.
Good welds can be attributed to correct selection and manipulation of

the electrode and welding current.
A. The following skills must be performed in unison to achieve a weld of

acceptable quality.
1. The proper amperage
The proper amperage setting for any welding job is necessary to get
good penetration with minimum spatter. Correct amperage can be
identified somewhat by sound.
a. When the amperage is correct, a sharp crackling sound can be

heard.
b. A humming sound will indicate too low an amperage setting and
the deposited electrode will pile up, leaving a narrow, high bead
that has poor penetration and little strength.
c. A popping sound will indicate too high an amperage setting and
the bead will be flat with excessive spatter. The electrode will

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become red hot, and the metal along the edge of the bead will be
undercut.
2. Correct amp setting depends on the thickness of the

base metal and the diameter of the electrode.
3. Arc Length Learning to maintain the correct arc length
for the electrode you are using is necessary in order to be
successful.
Arc length is the distance from the tip of the bare end of
the electrode to the base metal.
Arc length is equal to the diameter of the bare end of the
electrode.
4. Electrode Angle
The correct angle of the electrode will depend on the
type of weld that is to be completed.
Hold the electrode at a 90 degree angle to the work as
viewed from the end of the two plates being joined, and 5
to 15 degrees in the direction of travel.
5. Speed of Travel
Correct speed of travel affects the amount of
electrode deposited and the uniformity of the bead.
It should produce a bead that is 1.5 to 2 times the
diameter of the bare end of the electrode.
B. Following proper procedures when preparing to weld and striking the

arc will develop confidence in your abilities.
1. Prepare the work area so that everything is ready and

convenient before you start.
2. Make a final check to see that flammable materials are out of
the way and that unnecessary tool are not lying around.
3. Be sure the machine is turned off.
4. Set the machine to the desired amperage.
5. Insert the bare end of the electrode in the electrode holder and
hold the end of the electrode about 1 inch above the metal at
the point where the weld is to be started.
6. Turn the welder on.
7. Lower the helmet over your eyes, bring the electrode in contact
with the work and withdraw it slightly.
Current jumps this small gap creating the electric arc.

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The moment the arc is struck the concentration of intense heat,
estimated between 6,000 and 9,000 degrees F, melts the base
metal and the end of the electrode forming a molten metal pool
called a crater.
8. There are two methods used in starting the arc.
A.A striking movement is similar to striking a match.
B.A tapping movement is where the electrode is quickly tapped
on the surface of the metal to prevent it from sticking to the
base metal.
C.If the electrode is not instantly pulled away it will fuse with
the base metal and stick.
D.If the electrode is pulled too far away, the arc will be
extinguished.
9. Raise the tip of the electrode to about 3 /16 inch above the base
metal. This forms a long arc which is held for a three count in
order to preheat the base metal.
10. Lower the electrode to the correct arc length.

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Welding Techniques and Procedure
Multiple Choice:

1. What variable of SMAW does affect the amount of

electrode deposited and the uniformity of the bead?
A. length of arc C. speed of travel
B. manipulation of electrode D. angle of electrode
2. Correct amperage can be identified somewhat by sound.
A. sharp crackling sound C. popping sound
B. humming sound D. all of the above
3. ________________ depends on the thickness of the base

metal and the diameter of the electrode

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A. Length of Arc C. Arc Length Learning
B. Speed of Travel D. Correct amp setting
4. If the electrode is not instantly pulled away it will fuse

with the base metal and _______.
A. Stick C. Burn
B. Break D. Absorb moisture
Answer Key No. 1.1-6
Welding Techniques and Procedure
1. C
2. C
3. D
4. A

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Safe Welding Practices
Objectives:
3. Familiar with the welding hazards.

4. Prevent welding hazards during welding.
Hazard and Safety Precautions
Accidents by electrical energy

Causes (mechanical/manual)
 Faulty or missing insulation on current-carrying parts.
 Faulty or missing protection equipment (protection clothing,
insulating plates. Protection against rain).
 Ignorance or carelessness of welder which may lead to accidents
in spite of excellent safety instructions.
Contact to current carrying parts having faulty or missing

insulation lead to accidents, since man body become parts of the
electrical circuit.
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Current carrying parts in welding are:
1. Plugs
2. Terminals
3. Power Lines and Cables, Welding Cables
4. Sources of Welding Current
5. Electrode Holder
Examples:
 Safety covers are missing or damaged.
 During operation of machine connections are tightened cables
are change (polarity) power source is moved transported
maintenance assignments performed.
Prevention:
 Weld only with faultless protective clothing.
 During welding and replacement of electrode, use only dry
gloves.
 Service shoes must not have steel nails or steel linings
underneath the soles. Work only using insulating platforms and
if, necessary, additional insulating body shields during welding
in lying, sitting, or kneeling positions, especially vessels.
 If it rains, perform welding underneath rain proof.
Ignorance or carelessness of the welder

In spite of the prevention of all circumstantial causes,
insufficient in the prevention of accidents and careless manners
of the welder cause accidents.
Examples:
 Replacing electrodes without gloves
 Removing parts of the protective clothing (for instance during
summer)
 Sliding the electrode holder beneath arm
 Failure to use available insulating platforms and other
protective gears
Prevention:
 Strive for sufficient instruction
 Be safety conscious
 Issue training manuals for safety
 Use of protective clothing is imperative

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 Do not only avoid own accidents but consider also other peoples
risks and damages caused by accidents
 Do not be careless and irresponsible in your work.
A typical warning label attached to welding equipment
WARNING
Read and Understand this Warning Protect Yourself and Others
ELECTRIC SHOCK can kill ENGINE EXHAUST GASES can

kill
 Do not permit electrically live
parts or electrodes to contact  Use open, well ventilated areas
skin. . .or your clothing or or vent the engine to the outside
gloves if they are wet.
 Insulate yourself from work HIGH VOLTAGE can kill
and ground
 Do not touch electrically live
parts
 Stop engine before servicing
FUMES AND GASES are
dangerous to your health
MOVING PARTS can cause
 Keep fumes and gases from serious injury
your breathing zone head out
 Keep clear of moving parts
of fumes
 Do not operate with protective
 Keep your head out of fumes
covers, panels or guards
 Use enough ventilation or removed
exhaust at the arc or both _____________________________
_
ARC RAYS can injure eyes
and burn skin
 Only qualified personnel should
 Wear correct eye, ear and install, rise or service this
body protection equipment
 Read operating manuals for
details
Read and understand the manufacturer’s instructions and your

employer’s safety practices
DO NOT REMOVE THIS WARNING

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Note:
 Electrical connections must be tight.
 Terminals for welding leads and power cables must be shielded
from accidental contact by personnel or by metal objects.
 Cables must be used within their current carrying and duty
cycle capacities; otherwise, they will overheat and breakdown
the insulation rapidly.
 Cable connectors for lengthening leads must be installed
Electrical devices of various kinds are common in welding

shops. All electrical devices are hazardous, but some use extremely
high and dangerous voltages. All equipment and areas where 220
volts or more are used must be well marked. Well-trained and
competent technicians must only do the installation and repair of
electrical equipment.
Note:
Electrical connections must be tight. Terminals for welding
leads and power cables must be shielded from accidental contact by
personnel or by metal objects. Cables must be used within their
current carrying and duty cycle capacities; otherwise, they will
overheat and breakdown the insulation rapidly. Cable connectors for
lengthening leads must be installed
Electrical Hazards
Electrical devices of various kinds are common in welding shops. All
electrical devices are hazardous, but some use extremely high and
dangerous voltages. All equipment and areas where 220 volts or more
are used must be well marked. Well trained and competent
technicians must only do the installation and repair of electrical
equipment.
Hazardous Obstacles
Safety hazards or obstacles in the shop should be well marked.
Signs, Fences or barriers should be erected while temporary hazards
are present, so that all workers are fully aware of them. Permanent
hazards are often painted with yellow and black stripes to create high
visibility
Suffocation Hazards
Gases that are heavier than air or lighter than air can be
extremely dangerous to welders in closed or confined spaces. Argon
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and Carbon Dioxide are examples of heavier-than-air gases. Helium is
an example of a lighter-than-air gas. These gases are colorless and
odorless and will displace the oxygen in a closed space. Argon, for
example, can asphyxiate a person in about seven seconds. Closed
spaces must be well ventilated when heavier-than-air or lighter-than-
air gases to be used. If proper ventilation cannot be obtained, the
welder must go to the space using an air-supplied purifier.
Welding on Hazardous Containers

Unless you are trained in the proper procedures for doing so,
never try to weld or cut a container that has held flammable or
hazardous materials. Such a container may explode. Proper
procedures are described in the American Welding Society (AWS)
Standard F4. 1-88, Recommended Safe Practices for the Preparation for
Welding and Cutting of Containers That Have Held Hazardous
Substances. You should also consult with the local fire marshall
before welding or cutting such containers.
Safe Welding Practices

Multiple Choice:
1. All that is listed below are Current carrying parts in welding
except:
A. Welding Mask C. Terminals
B. Plugs D. Power Lines and Cables
2. Electrical connections must be ________.

A. loose C. arranged
B. tight D. disconnected
3. Open wires inside the workshop is an example of

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A. Physical hazards C. Electrical hazards
B. Chemical hazards D. Biological hazards
4. The following are physical hazards except

A. mists C. poor illumination
B. messy area D. too much heat
5. These hazard causes arc flash and burn skin.

A. fumes and gases C. moving parts
B. octopus connections D. arc rays
Answer Key No. 1.1-7
Safe Welding Safety Practices
1. A
2. B
3. C
4. A
5. D

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WRITTEN TEST
(Summative Test)
Multiple Choice:
1. E 6010 electrode is designed to work best on:

A. AC-DC C. DCRP
B. AC only D. DCSP

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2. The correct travel speed will result in a well formed weld bead that
shows:
A. spatter C. thin stringy weld
B. good fusion D. heavy weld w/ much convexity
3. The correct length may vary according to

A. welding position C. type of welding machine
B. type of current D. kinds of base metal
4. Welding pipelines and related facilities is API number

A. 1102 C. 1104
B. 1103 D. 1105
5. Which of the following welding codes that covers all aspects of

design and manufacturers of boiler sand pressure vessel?
A. AWS C. API
B. ISO D. ASME
6. The maximum root face made in preparing single V-groove is:

A. 3/32” C. 1/8”
B. 5/32” D. ¼”
7. Incomplete sidewall fusion is found between

A. Heat affected zone and base metal
B. Root pass and Hot pass
C. weld and base metal
D. between weld passes

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8. The appropriate size of tack weld in joining the work piece is
A. 5 mm C. 15 mm
B. 10 mm D. 20 mm
9. When electrode coatings absorb moisture, it is most likely that the

weld will have
A. excess penetration C. too much undercut
B. shallow penetration D. porosities
10.What causes undercut?

A. low ampere C. too long arc
B. high ampere D. poor penetration of work piece
11.The correct groove angle in preparing butt joint is

A. 30 degrees C. 50 degrees
B. 40 degrees D. 60 degrees
12.To prevent electrical hazards, the following must have to be

observed except,
A. electrical connections must be tight
B. use of PPE is imperative
C. replacing electrode without gloves
D. be safety conscious
13. Octopus connections inside the workshop is an example of

A. physical hazard C. electrical hazard
B. chemical hazard D. biological hazard

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14. Hazards that causes arc flash and burn skin.
A. fumes and gases C. moving parts
B. octopus connections D. arc rays
15.The following are physical hazards except:
A. mists C. moving parts
B. messy area D. arc rays
Answer Key
WRITTEN TEST
(Summative Test)
1. C
2. A
3. D
4. C
5. D
6. C
7. C

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8. B
9. D
10. C
11. A
12. C
13. C
14. D
15. D

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Evidence Plan
QUALIFICATION SMAW NC II
UNIT OF COMPETENCY Weld Carbon Steel Pipes using SMAW
COVERED
Ways in which evidence will be collected:

[tick the column]
Demonstration
Written Test
Questioning
with Oral
Interview
The evidence must show that the candidate……
Identified the essential variables of SMAW Welding.  
Identified the different welding codes and standards.  
Explained the application of the different welding codes and 

standards.
Identified acceptable weld profiles.  
Identified the different weld defects; its causes and 
 
remedies.
Interpreted welding procedures and specifications.  
Performed root pass* 
Welded subsequent/filling passes* 
Performed capping* 
Rectified weld defects * 
Applied weld techniques* 
Observed safety practices   
NOTE: *Critical aspects of competency

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TABLE OF SPECIFICATION
Objectives/Content # of items/
Knowledge Comprehension Application
area/Topics % of test
 Essential
variables of 3 2 5
SMAW
Welding. (15%) (10%) (25%)
 Welding codes 3 3
and
(15%) (15%)
standards.
 Acceptable 1 1
weld profiles. (5%) (5%)
 Weld defects; 2 2 1 5
its causes and
(10%) (10%) (5%) (25%)
remedies.
 Welding
3 3
procedures
and (15%) (15%)
specifications.
 safe welding 1 1 1 3
practices (5%) (5%) (5%) (15%)
9 7 4 20/
TOTAL (45%) (35%) (20%) 100%

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Performance Test
Specific Instruction for the Candidate
Qualification SMAW NC II
Unit of Competency Weld Carbon Steel Pipes Using SMAW

List of Equipment, Tools and Materials:
Equipment
Quantity Description
1 unit AC/DC Welding Machine
1 unit Portable Grinder
1 unit PPE’s
Tools
1 pc Steel brush
1 pc Chipping Hammer
1 unit Carpenter’s square

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Weld Carbon Steel Pipes YUNUS BANUA
using SMAW Revision # 00
Materials
1 pair Pipe, schedule 8,6 inches length beveled
cut on both ends
25 pcs E7018 electrodes, 3mm diameter
10 pcs E6011 electrodes, 3 mm diameter
General Instruction: Given the necessary materials, tools and equipment, the
candidate must be able to weld carbon steel pipe in 2G position using SMAW within
four (4) hours.
Specific Instruction:
1. Obtain necessary materials, tools from the assessor.
2. Prepare work piece in accordance to the WPS.
3. Perform the Root Pass.
4. Let the assessor inspect finished Root Pass.
5. Perform Subsequent Filling passes.
6. Let the assessor inspect Filling Passes.
7. Perform the Final/Cover Pass.
8. Submit output/work piece to the assessor for final
inspection.

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PERFORMANCE CRITERIA CHECKLIST
CANDIDATES NAME
TRAINERS NAME
QUALIFICATION SMAW NC II
UNIT OF COMPETENCY 1. Weld Carbon Steel Pipes using SMAW
COVERED
DATE OF ASSESSMENT
TIME OF ASSESSMENT
INSTRUCTIONS FOR DEMONSTRATION
Given the necessary materials, tools and equipment, the candidate must be able to
weld carbon steel plates in 6G position using SMAW within four (4) hours
Please check (/) to show if evidence is
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demonstrated
Yes No N/A
 Performed root pass
 Cleaned root pass
 Welded subsequent/filling pass
 Performed capping
 Interpreted drawing
 Knew materials and consumables
 Knew welding codes
 Knew weld defects
 Applied weld techniques
 Handled materials, tools and equipment
 Observed safety practices
 Passed weld visual inspection
The candidate’s demonstration was:
Satisfactory Not Satisfactory
Candidates Signature: Date:

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Assessors Signature : Date:
QUESTIONING TOOL
RATING SHEET FOR ORAL QUESTIONING
QUESTIONS Satisfactory
response
YES NO
1. What causes porosities?
2. What are the essential variables of SMAW process?
3. What is arc length?
4. What effect will it have on the weld if the arc length is too long
? too short?
5. What is warpage or distortion?
6. How would you prevent warpage or distortion?
7. What causes poor penetration?
8. What is the ideal root face of a single-V groove butt joint?
9. How would you prevent cracking on welded materials?
10. What is the ideal height of weld bead?
11. What are welding related injuries?
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12. How would you avoid welding related injuries?
13. What measures would you apply if the welding machine
emitted smoke while in used?
Feedback to the Candidate:
The Candidate’s underpinning knowledge was:
Satisfactory Not Satisfactory

Trainee’s signature: Date:
Trainer’s Signature: Date:
MODEL ANSWER FOR QUESTIONING TOOL
1. Electrode absorbed moisture.

2. a. arc length
b .current setting
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c. size and type of electrode
d. angle of electrode
e. rate of travel
3. Arc length is the distance from the tip of the electrode to the surface of the work piece. Varying the arc distance affects
the voltage input during welding.
4. a. Too high an arc length produces a flat weld bead, spatters occurs , and there will be no fusion between weld bead
and the metal.
b. Too short an arc length produces slag inclusions.
5. War page or distortion is the deformation of parent metal due to high heat input.
6. Avoid too much heat input to avoid war page and distortion. Let parent metal cool-off placing the next weld pass/ess.
7. Too low current setting produces poor penetration.
8. 3 mm is the standard height for root face.
9. Avoid too much heat input to avoid possible weld cracking.
10. The ideal height for weld bead in the cover is 3mm, and 3mm height for root reinforcement.
11. Arc flash, radiation, suffocation from toxic fumes and gases are some related injuries from welding.
12. Proper use of Personal Protective Equipment helps to avoid some of the related injuries from welding.
13. Shut down the machine, and then call for the trainer’s attention should smoke occurs on the welding machine while
on the process of welding.

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Shielded Metal Arc Welding Shop Layout

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Inventory of Training Resources
Resources for presenting instruction
 Print Resources As per In Remarks
Training Inventory
Regulation
CBLM
1. Perform work safety 25 25 Available
2. Contribute to quality system 25 25 Available
3. Use hand tools 25 25 Available
4. Interpret blueprints 25 25 Available
5. Perform industry calculations 25 25 Available
6. Prepare weld materials 25 25 Available
7. Set-up welding equipment Available
8. Fit up weld materials 25 25 Available
9. Repair welds 25 20 5 for

reproduce
10. Weld carbon steel plates 25 25
using SMAW Available
11. Weld carbon steel pipes 25 25

using SMAW
 Non Print Resources As per In Remarks

Training Inventory
Regulation
1. DVD 1 1 Available
2. CD-ROM 1 1 Available
3. Power Point Presentations (Weld 1 1 Available
carbon steel plates and pipes using
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SMAW)
Resources for Skills practice
______________________________
 Supplies and Materials As per In Remarks
Training Inventory
Regulation
Electrode 3.2mm E6011 7 boxes 7boxes Available
Electrode 3.2mm E7018/E6013 7 boxes 7 boxes Available
Mild steel plate 10mmx150mmx6m 25 pcs 25 pcs Available
Carbon steel pipe, schedule 40 dia. 150 2 pcs 2pcs Available
x 3m
Filter lense 20 pcs 20 pcs Available
Lense clear glass 20 pcs 20 pcs Available
Cut off disc 6mm x 15mm x 100mm 20 pcs 20 pcs Available
Power saw blade 5 pcs For purchase
Metal chalk 1 box 1 box Available
 Tools As per In Remarks
Training Inventory
Regulation
Chipping hammer 10 pcs 10 pcs Available
Steel brush 10 ps 10 pcs Available
Ballpeen hammer 10 pcs 10 pcs Available
Plier/tong 10 pcs 10 pcs Available
Files-bastard cut 10 pcs - For purchase
Headshield/helmet 10 pcs 10 pcs Available
Leather jacket 10 sets 10 sets Available
Leather gloves,long 10 sets 10 sets Available
Safety goggles,wide vision,clear 2 pcs - For purchase
Oxy-acetylene goggles 8 pcs 8 pcs Available
Try square 300mm long 10 pcs 10 pcs. Available
Steel square, 300 mm long 10 pcs 10 pcs Available

Date Revised:
Developed by:
74
using SMAW
Files-half round 10 pcs - For Purchase
Fillet gauge 2 pcs - For Purchase
 Equipment As per In Remarks

Training Inventory
Regulation
Arc welding machine AC/DC and 10 units 10 units Available
accessories
Welding table/positioners 10 pcs 10 pcs Available
Electrode oven 1 unit 1unit Defective
Automatic gas cutting machine 1 unit - For Purchase
Portable disc grinder 5 units 5 units Available
Exhaust fan 1 unit - For Purchase
Power hacksaw 1unit 1 unit Available
Anvil 2 units 2unit Available
Workbench w/ bench vice on 4 corners 2 units 2 unit Available
Oxy-acetylene/Oxy-LPG cylinder with 2 sets 2 sets For Refill
content
Pedestal/ bench grinding machine 1 unit 1unit Available
Industrial fan 1 unit 1unit Available
Note: In the remarks section, remarks may include for repair, for
replenishment, for reproduction, for maintenance etc.
Prepared by:
Gianne Marini N. Mesa

Trainer
August 13, 2019

Date Revised:
Developed by:
74
using SMAW

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COMPETENCY BASED LEARNING MATERIAL

Sector : METALS AND ENGINEERING

Qualification Title: SMAW NC II

Unit of Competency: WELD CARBON STEEL PIPES USING SMAW

Module Title: : WELDING CARBON STEEL PIPES USING SMAW

EMN TECHNICAL INSTITUTE TRAINING AND ASSESSMENT CENTER

Date Developed: Document No.

No. Unit of Competency Module Title Code

Date Developed: Document No.

UNIT OF COMPETENCY: Weld Carbon Steel Pipes using SMAW

NOMINAL DURATION : 60 HRS

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

LO1. Weld carbon steel pipes in horizontal position (2G)

1. Root penetration not exceeding allowable tolerances specified by

2. Weld capping/final pass not exceeding allowable tolerances

3. Finish weldment visually acceptable in accordance with welding

Date Developed: Document No.

1. Root penetration not exceeding allowable tolerances specified by

Date Developed: Document No.

The student/trainee must be provided with the following:

Bead Denotes the appearance of the finished weld

2G 2 stands for horizontal and G stands for

DCSP The arc welding leads are arranged so that

DCRP In case of DC polarity, current flows only in

Concavity Maximum distance from the face of a concave

Date Developed: Document No.

Fillet Weld A type of weld which has a triangular cross

Flat Position The axis of the plate and weld is horizontal.

Overhead Position The axis of the plate and weld is both in

Penetration The distance from the original surface of the

Profile Geometrical structure of the weld

Root of Weld Part of a weld farthest from the application of

Stick Welding Other term for SMAW process

Date Developed: Document No.

WPS Welding Procedure Specification

Date Developed: Document No.

Learning Activities Special Instructions

Date Developed: Document No.

Refer to marking schedule for acceptance

Check your work by comparing to the

Ask your trainer to demonstrate the process.

If you pass, you can proceed to the next activity.

Date Developed: Document No.

Date Developed: Document No.

Essential Variables of SMAW Welding

1. Explain the essential variables of SMAW Welding.

Welding is a practical skill that requires continual practice and

The Five Essential Variables in SMAW (Stick) Welding

The welding current or amperage is essential to producing welds with

The amperage is set from the recommended ranges according to the

Size E6010/E6011 E7018

Some electrodes are designed to work best on a given Current and

Some electrodes are designed to work best on DCEN while others

Illustration below gives an idea of the evaluation process.

The welding machines used in SMAW are known as Constant Current

Date Developed: Document No.

The amount of weld metal deposited (weld deposition rate) and

There are a variety of electrodes available for welding a wide range of

The following is a brief description of the most commonly used