Remediation Lesson

in SMAW NC II
FIRST QUARTER
 SMAW NC II
SHIELDED METAL ARC WELDING (SMAW) NC II

The Shielded Metal Arc Welding (SMAW) NC II Qualification consists of

competencies that a person must achieve to weld carbon steel plate and
pipe components as specified by layout, blueprints, diagrams, work order,
welding procedure or oral instructions using shielded metal arc welding
equipment.

This Qualification conforms with American Welding Society (AWS) D 1.1

Structural Welding Code; American Society of Mechanical Engineers (ASME)
IX Boiler and Pressure Vessel Code; American Petroleum Institute (API) 1104
Code for Gas and Oil Pipeline Facilities; and International Standards
Organization (ISO) 9606-1 Qualification of Welders for Steel.
The Units of Competency comprising this qualification include the following:

Code No. BASIC COMPETENCIES

500311105 Participate in Workplace Communication
500311106 Work in Team Environment
500311107 Practice career professionalism
500311108 Practice occupational health and safety procedures

Code No. COMMON COMPETENCIES

MEE722201 Apply Safety Practices
MEE721202 Interpret Drawings and Sketches
MEE721203 Perform Industry Calculations
MEE721204 Contribute to Quality System
MEE721205 Use Hand Tools
MEE721206 Prepare Weld Materials
MEE721207 Setup Welding Equipment
MEE721208 Fit up Weld Materials
MEE721209 Repair Welds

Code No. CORE COMPETENCIES

MEE721306 Weld Carbon Steel Plates and Pipes Using SMAW
 Objective of the Lesson:
At the end of the lesson, the learners were expected to:
1. Identify the pipe welding positions
2. Discuss the pipe welding procedures.
3. Enumerate the equipment used in pipe joint fit up and
preparation
4. State the pipe preparation
5. Narrate the 6G pipe welding process Using SMAW
PIPE WELDING POSITIONS
 Matching Type: Match column A with column B by writing the letter of the
correct answer on the blank provided before each nmber
COLUMN A COLUMN B
_____1. This position inclines the pipe at a 45° angle to create
a sloping surface. The pipe is fixed, as with 5G, and the
welder must move around the pipe. This is the most
A.
advanced of the four positions and requires a greater level
of expertise from the pipe welder.
_____2. This position places the pipe upright in a vertical
position. The pipe can be rotated along the vertical (Y) axis,
B.
with the welder remaining stationary. The welding is
performed horizontally on the side of the pipe.
______3. This position places the pipe horizontally. The pipe can C. D.
be rotated along the horizontal (X) axis, with the welder
remaining stationary. The weld is completed on the top of the
pipe and is the most basic of the pipe welding positions.
______4. The 5G position places the pipe horizontally but, unlike
with the 1G position, the pipe cannot be rotated. Instead, the
welder must move around the stationary pipe in a vertical
direction to create the weld.
 Welding Positions:
Pipe welding has four positions:

1G 5G
The horizontal rolled position. In this position the The horizontal fixed position. The pipe is stationary
pipe is horizontal and it is being rolled so that and not rolling as you weld, which makes it more
you, the welder, are actually in a flat position challenging.
relative to the pipe. It's the easiest pipe
welding position.
 2G:
The vertical position. The 2G position is where the
6G
Pipe inclined fixed position. 6G is the most
pipe you are welding is vertical and you are difficult of the pipe welding positions because
welding in the horizontal. the pipe is at a forty five degree angle and it is
not rolling. And therefore you will need to be
able to weld on all four positions to finish the 6G
weld.
ATTENTION:

The positions do not refer to the weld. This

refer to the pipe. For example, if you are welding
in the 6G position the pipe is fixed and at an
incline. Not you or the weld.

Also, the letter 'G' stands for Groove Weld.

And the majority of pipe welds are groove
welds. Lastly, 3G and 4G welding positions do
not exist.
 Pipe Welding Tips and Procedures:

If you can't make a single pass then go with multi-layer

beads. The rule of thumb is to use one layer of beads for
each one eighth inch wall thickness of the pipe.

A common welding technique using the SMAW process is

to weave your layer beads. But you should always lay a
bead over a cleaned weld to avoid slag being deposited
in the filler material.

The most common type of joint used for welding together

pipe is a butt joint. Very simply, you take two pipes and
put them together and now you have a butt joint to weld.

But if you are welding thicker walled pipe then you are
going to bevel a V or U butt joint. Singles only.
PIPE JOINT FIT UP AND
PREPARATIONS
 Pipe Joint Fit Up and Preparation!
1. Remove any material that will negatively affect your
weld. That includes any oil or paint, rust or slag, and
scale, etc.
2. Be sure that the weld joint is uniform and as smooth as
possible on the surface of it.
3. A well cut bevel is crucial to the success of your pipe
welding procedure. It must be done properly.
4. You can make a bevel using a grinder or a cutting
torch. You can also machine it. You can hand cut
bevels using attachments to a grinder, or you can use
beveling machines.
 Using A Cutting Torch For Beveling Pipe:

If you are working out in the field most welders defer to a

cutting torch for making bevels. So be sure any slag you
created from cutting with the torch is totally gone.

For small pipe use the angle iron. For larger pipe use the I beam.

Note: alignment tolerance is twenty percent of the thickness of

the pipe wall. In other words, you can be off by a very little bit
when aligning pipe so get it right.
Using A Cutting Torch For Beveling Pipe:
PIPE ALIGNMENT TOOL
Pipe Alignment Tool Sample DIY
pipe clamp
PIPE TACK WELDING
 The Tack Weld:

Tack welding is another very important aspect to pipe

welding. Tack welds hold your piece together in the
alignment and position you want. If it is not in the right
position or alignment then you simple remove the tack
weld and re-position your material.

In tack welding pipe, another rule of thumb to use is that

for the tack weld length should not be more the two
times the wall thickness of the pipe. The depth of the
tack should two thirds.
 The Tack Weld:

If you are welding .5" pipe then you just need 2

tacks welds on opposite sides of each other.

4 tacks are used for pipe that is standard in size.

A tack weld needs to have the same penetration

and quality as the weld bead you will lay to finish
the job.
Some say that a three sixteenths
electrode is the maximum you
should go for multi layering welding
for the root pass because if it's
bigger you may not get good
penetration and fusion of the weld,
and without any slag or undercutting
of the weld.
 Using Spacers:

A spacer is a commonly used tool for achieving a well aligned

joint. A spacer is a piece of metal that has been machined
specifically for the joint you are welding.

You will also find language referring to spacers as a

'backing ring' or a 'chill ring’
.
Spacers are very handy because you can use them for
several purposes which include aligning pipe, making tack
welds easier, keeping a root opening at the desired amount
as you prepare and perform your welding, and keeping slag
and spatter from getting in the pipe.
Tacking the Schedule 80 Pipe
Performing 6G pipe welding
Using SMAW
How to perform 6G pipe welding using SMAW
 ESSENTIALS FOR PROPER WELDING PROCEDURES
C Correct Current
L Correct Arc Length/ Arc Gap
A Correct Angle
M Correct electrode movement/ travel speed

S Correct electrode size

WELD DEFECTS
Defects may occur due to the following
reasons;
1. Incorrect welding parameters
2. Inappropriate welding procedures
3. Poor process condition
4. Inappropriate selection of filler metal and
parent metal
5. Unskilled welder or welding operator
6. Incorrect job preparations
Classification of Defects:
Defects can be classified as external defect (also
known as visual defect or surface defect) or internal
defect (also known as hidden defect or subsurface
defect).
• External defects are those which are found on the
surface itself.
• Internal defects are those which exist in the material
at some depth.
1. CRACKS:

It is the most dangerous of all defects. Cracks may be of any size

or shape; it can be either microscopic or macroscopic. Cracks may
appear anywhere i.e. on the surface, subsurface, at any depth, or at
the root. The crack occurs when localized stress exceeds the ultimate
Tensile Stress (UTS) of the material. It may propagate within the material.
2. POROSITY & BLOW HOLES:
Porosity is a cavity-like discontinuity and occurs due to the
entrapment of gases in the molten weld pool. These
entrapped gases don’t get a chance to escape from the
molten weld pool and hence cause porosity or blowholes.
Porosity is basically a small pore or void, whereas, blowholes
are comparatively larger hole or cavity.

Porosity may be present on the surface or inside the weld

metal. Porosity can occur individually or it may occur in
groups also (mostly), group of porosity is known as cluster
porosity.

Gases that are entrapped and cause porosity are

mostly Hydrogen, Carbon mono oxide, Carbon dioxide,
Nitrogen, and Oxygen. These gases are formed due to the
fluxes present on the welding electrode, Moisture, Oil,
Grease other foreign contaminants present on the joint, or
on the welding electrode or on the filler wire. Insufficient
flow of shielding gas also causes porosity in GMAW, FCAW,
GTAW & PAW welding processes.
3. UNDERCUT:
Undercut appears as a narrow groove on the base metal adjacent to
the weld metal along the edge. Undercut always runs parallel to the
weld metal. It acts as a stress raiser during fatigue loading.
4. UNDERFILL:
When the weld metal surface
remains below the adjacent
surface of the base metal
then it is called an underfill.
Basically, Underfill is
undersized welding.
5. LACK OF PENETRATION (INCOMPLETE PENETRATION):
When the weld metal doesn’t completely penetrate the joint, then it is
called a Lack of Penetration or Incomplete Penetration. It is one of the
most dangerous defects since it acts as a stress raiser, and hence crack
may originate or propagate from there.
6. LACK OF FUSION (INCOMPLETE FUSION):
It is the lack of proper melting (or proper
fusion) either between the weld metal
with the base metal or one layer of the
weld with the other layer. Lack of fusion is
also called as Cold lapping or cold
shuts. One of the most prominent reasons
for the cause of lack of fusion is poor
welding techniques. Lack of fusion is an
internal defect, but it can occur on the
external surface too if the sidewall of
parent metal doesn’t get properly fused
with the base metal, as shown in the
below figure and for this case lack of fusion
can also be called as ‘lack of sidewall
fusion’.
7. SPATTERS:

Spatters are small globular

metal droplets (of weld
metal) splashed out on
the base metal during
welding. Spatters stick on
the base metal hence
can be removed by wire
brush or buffing.
8. OVERLAP:

Overlap occurs due to

the overflow of weld
metal on the surface of
base metal. During
welding, molten metal
overflows on the base
metal without fusing with
the base metal.
9. EXCESSIVE PENETRATION:

When the penetration of weld

metal is too high, through the
joints, then it is called as
excessive penetration. It acts as a
notch where stress concentration
takes place. In addition to this, it
results in economical wastage
too.
10. INCLUSION:
Any entrapped solid material (either metallic or non-metallic) in the weld
metal, is called as Inclusion. Tungsten, Oxides, Slag, and Flux are some of
the common foreign materials which are entrapped in the molten weld
pool and form inclusion.
WELD DEFECTS SA ROOT PASS
WELD DEFECTS SA CAPPING/ COVER PASS
References:
https://www.wcwelding.com/pipe-welding.html

https://www.weldingandndt.com/welding-defects/