Self-learning Instructional Material SY 2020-2021
GRADE
Hilongos National Vocational School
Senior High Department 12
Self-learning Instructional Material
In
Shielded Metal Arc Welding
NAME:
___________________________
GRADE & SECTION:
____________________
SUBJECT TEACHER: JOSE N.
GLAMAYO
NOT FOR SALE. FOR DISTANCE LEARNING PURPOSES ONLY.
Important: Please DO NOT LOSE this.
Drop this in the box located at the
Brgy.
Self-learning Instructional Material SY 2020-2021
WEEK 5 AND 6
INFORMATION SHEET 1
Learning Outcome:
Identify weld defects, Causes and Remedies
What is a welding defect?
Welding defect - is a kind of discontinuity found after welding because of wrong manipulation/or not following proper
welding procedure.
What do you mean by discontinuity?
Discontinuity - It is a kind of lapses that can weakened the soundness of welding.
Why does welding defects occur?
How can those welding defect be remedied?
What are the different types of Welding Defects?
Welding defects are generated in a welding job due to the faulty or poor technique used by the inexperienced or
unskilled welder or due to fundamental difficulties in the welding operation. An ideal weld or good weld should be such
that adequate fusion exists between the filler metal and edge preparation together with good penetration.
Types of Welding Defects:
Welding defects are broadly classified into two categories, and these are:
1. External welding defects (Defects occur on the upper surface of the welded work).
2. Internal welding defects (Defects occur under the surface of the welded work).
I. External Welding Defects:
The various types of external defects with their causes and remedies are listed below:
A. Weld Crack
This is the most unwanted defect of all the other welding defects. Welding cracks can be present at the
surface, inside of the weld material or at the heat affected zones
Crack can also appear at different temperatures:
1. Hot Crack – It is more prominent during crystallization of weld joints
where the temperature can rise more than 10,000-degree Celsius.
2. Cold Crack – This type of crack occurs at the end of the welding process where
the temperature is quite low. Sometimes
cold crack is visible several hours after welding or even after few days.
Causes of Weld Crack:
1. Poor ductility of the given base metal
2. The presence of residual stress can cause a crack on the weld metal.
3. The rigidity of the joint which makes it difficult to expand or contract the metals.
4. If there is high content on sulphur and carbon then also the cracks may appear.
5. Using hydrogen as a shielding gas while welding ferrous materials.
6. Wrong electrode
7. Weld parts size unbalanced
8. Faulty preparation
Remedies for Weld crack:
1. Using appropriate materials may decrease the chances of crack.
2. Preheating the weld and reducing the cooling speed joint helps in reducing crack.
3. Reduce the gap between the weld joints by using reasonable weld joints.
4. While welding releases the clamping force slowly which increases fill to capacity of welding material.
5. Design structure to eliminate rigid joints.
6. Avoid weld on string beads.
7. Keep end free to move as long as possible.
Self-learning Instructional Material SY 2020-2021
8. Adjust weld size to part size.
9. Allow joint to proper and uniform gap.
10. Work with amperage as low as possible.
B. Undercut 1
When the base of metal melts away from the weld zone, then a groove is formed in
the shape of a notch, then this type of defect is known as undercut. It reduces the fatigue
strength of the joint.
Visible undercut generally associated with proper welding techniques or excessive
welding current.
It is generally located to the junction of weld metal and base metal at the toe or
root of the weld.
Causes of Undercut:
1. If the arc voltage is very high then this defect may occur.
2. If we use the wrong electrode or if the angle of the electrode is wrong, then also the defect may form.
3. Using a large electrode is also not advisable.
4. High electrode speed is also one of the reasons for this defect.
Remedies for Undercut:
1. Reduce the arc length or lower the arc voltage.
2. Keep the electrode angle from 30 to 45 degree with the standing leg.
3. The diameter of the electrode should be small.
4. Reduce the travel speed of the electrode.
C. Spatter
When some metal drops are expelled from the weld and remain stuck to the surface, then this defect is known as
spatter.
Causes of Spatter:
1. High welding current can cause this defect.
2. The longer the arc the more chances of getting this defect.
3. Incorrect polarity
4. Improper gas shielded may also cause this defect.
Remedies for Spatter:
1. Reducing the arc length and welding current
2. Using the right polarity and according to the conditions of the welding
3. Increasing the plate angle and using proper gas shielding
4. Check shielding gas type and flow rate
D. Porosity
Porosity refers to small cavities or holes resulting from gas pockets in weld metal.
Causes of Porosity:
1. It occurs when the electrode is not coated properly.
2. Using a longer arc may also increase its chances.
3. Increased welding currents.
4. Rust or oil on the welding surface.
5. Moisture, for example from incorrectly stored electrodes or fluxes, humid shielding gas.
6. Insufficient gas shielding.
7. Welding onto small gaps filled with air.
Self-learning Instructional Material SY 2020-2021
Remedies for Porosity:
1. Proper selection of the electrode
2. Decreasing the welding current
3. Using smaller arc and slowing the process to allow the gases to escape 2
4. Remove rust or oil from the surface and use a proper technique
5. Rebake or use fresh welding consumables.
6. Dry or clean plate edges.
7. Check shielding gas type and flow rate.
8. Increase welding gap. When possible, apply butt joints instead of fillet or overlap welds.
Porosity is the result of gas being entrapped in solidifying weld material.
a. Uniformity Scattered Porosity – May be distributed throughout single pass weld or
throughout several passes of multiple pass welds.
b. Cluster Porosity – is a localized grouping of pores that may result from improper
initiation or termination of the welding arc.
c. Linear Porosity – may be aligned along:
1. A weld interface;
2. Root of the weld, and
3. A boundary between beads.
d. Elongated Porosity:
Piping porosity is a term for elongated gas pores.
Piping porosity in fillet welds normally extends from the root of the weld toward
the face.
E. Overlap
When the weld face extends beyond the weld toe, then this defect occurs. In this
condition the weld metal rolls and forms an angle less than 90 degrees.
Are usually/caused by incorrect welding procedure, wrong selection of
welding materials or improper preparation of the base metal prior to
welding.
Causes of Overlap:
1. Improper welding technique
2. By using large electrodes this defect may occur.
3. High welding current
Remedies for Overlap:
1. Use a proper technique for welding.
2. Use small electrode.
3. Less welding current.
F. Distortion
Distortion means contraction of weld metal during welding that forces
base metal to move.
Causes of Distortion:
1. A great number of passes with small diameter electrodes
2. Slow arc travel speed
3. High residual stresses in the plate to be welded
4. Using improper welding sequences
5. Too many and too thin beads, usually because the electrode is
too small.
6. Poor plate fit-up before welding.
7. Plates clamped insufficiently.
Remedies of Distortion:
Self-learning Instructional Material SY 2020-2021
1. Use the proper amount of weld metal as per the requirement of the joint. It will reduce the contraction forces.
2. Use an appropriate number of weld passes.
3. Place the weld near the neutral axis.
4. Use proper welding sequences.
5. Weld from both sides for the joint. Weld from the center out, in opposite directions.
6. Use a larger electrode. If possible, a high recovery type. 3
7. Compensate for shrinkage by fixing the work pieces with a counter-angle.
G. Burn-Through
Burn- Through refers to weld metal melting completely through base
metal resulting in holes where no metal remains.
Cause of Burn-Through:
1. Excessive heat input
Remedies of Burn-Through:
1. Select lower amperage. Use smaller electrode.
2. Increase and/or maintain steady travel speed.
II. Internal Welding Defects:
The various types of internal defects with their causes and remedies are listed below:
A. Slag Inclusion
If there is any slag in the weld, then it affects the toughness and metal
weldability of the given material. This decreases the structural performance of
the weld material. Slag is formed on the surface of the weld or between the
welding turns.
Is a non-metallic material trapped in the weld
metal or at the weld metal interface.
Generally, results from faulty welding technique
and improper access to joint for welding.
Causes of Slag:
1. Slag is formed if the welding current density is very small, as it does not provide the required amount of heat for
melting the
metal surface.
2. If the welding speed is too fast then also slag may occur.
3. If the edge of the weld surface is not cleaned properly then also slag may form.
4. Improper welding angle and travel rate of welding rod
Remedies for Slag Inclusion:
1. Increase the current density.
2. Adjust the welding speed so that the slag and weld pool do not mix with each other.
3. Clean the weld edges and remove the slags of previous weld layers.
4. Have a proper electrode angle and travel rate.
B. Incomplete Fusion
Incomplete fusion occurs when the welder does not accurately weld the
material and the metal pre solidifies which leads to a gap which is not filled with
the molten metal.
Incomplete Fusion – means incorrect welding techniques, improper
preparations of the materials for welding or wrong joint designs promote
incomplete fusion in welds.
Causes of Incomplete fusion:
1. It occurs because of the low heat input.
2. When the weld pool is very large and runs ahead of the arc.
3. When the angle of the joint is too low.
4. Incorrect electrode and torch angle may also lead to incomplete fusion.
5. Improper bead position
Self-learning Instructional Material SY 2020-2021
Remedies for Incomplete Fusion:
1. Increasing the welding current and decreasing the travel speed helps in removing the chances of incomplete fusion.
2. Reducing the deposition rate.
3. Increasing the joint angle.
4. Try to position the electrode and torch angle properly so that the edges of the plate melt away.
5. Positioning the bead properly so that the sharp edges with other beads can be avoided.
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C. Incompletely Filled Groove or Incomplete Penetration
These defects occur only in the butt welds where the groove of the metal is not filled completely. It is also called
as incomplete penetration defect.
Causes of an Incomplete Filled Groove: Remedies for Incomplete Filled Groove:
1. Less deposition of the weld metal 1. More deposition of the weld metal.
2. Use of improper size of the electrode 2. Use a proper size of the electrode
3. Improper welding technique 3. By using a proper welding technique.
Poor Penetration:
This condition may result from insufficient welding heat, improper joint design,
incorrect bevel angle or poor control of welding arc.
Under fill:
Results simply from the failure of the welder or welding operator to fill the joint with weld
metal.
Crack of weld:
Occurs in weld metal and base metal when localized stress exceed the ultimate
strength of the metal.
Cracks can be classified as either hot or cold types.
Poor Penetration:
Causes of poor penetration: Remedies for poor penetration:
1. Speed too fast 1. Use enough current to obtain desired penetration-weld slowly
2. Electrode too large 2. Select electrode according to welding groove size.
3. Current too low 3. Leave proper gap at the bottom of weld.
4. Faulty preparation
Warping:
Causes of warping: Remedies for warping:
1. Shrinkage of weld metal 1. Peen joint edges before welding.
2. Faulty clamping of parts 2. Weld more rapidly.
3. Faulty preparation 3. Avoid excessive space between parts.
4. Overheating at joint 4. Use proper sequence
5. Clamp or track parts properly back up tool.
6. Adopt a proper welding procedure.
Poor Fusion:
Causes of poor fusion: Remedies for poor fusion:
1. Wrong speed 1. Adjust electrode to match the joint.
2. Current improperly adjusted 2. Weave must be sufficient to melt side joint.
3. Faulty preparation 3. Select proper current and voltage.
4. Improper electrode size 4. Keep weld metal from flowing away from plates.
Self-learning Instructional Material SY 2020-2021
SELF 5
CHECK # 1
Multiple Choice: Directions: Read and analyze the statement carefully. Choose the correct answer and write the
letter only on your separate answer sheet
1. ______________________ are generated in a welding job due to the faulty or poor technique used by the
inexperienced or
unskilled welder or due to fundamental difficulties in the welding operation.
a. Spatter b. Porosity c. Penetration d. Welding Defects
2. ____________________ occurs when the depth of the welded joint is insufficient.
a. Incomplete Penetration b. Porosity c. Penetration d. Welding Defects
3. ____________________ is defined as the distance from the base plate top surface to the maximum extent of the weld
nugget.
a. Spatter b. Porosity c. Penetration d. Welding Defects
4. ____________________ is a group of small voids and blowholes are comparatively bigger isolated holes or cavities.
a. Spatter b. Porosity c. Penetration d. Welding Defects
5. ____________________ is the small metal particles that are thrown out of the arc during welding and get deposited on
the
base metal around the weld bead along its length.
a. Spatter b. Porosity c. Penetration d. Welding defects
6. __________________ is the change in the shape and difference between the position of two plates before and after
welding due to the temperature gradient present at various points along the joints.
a. Groove b. Hot tear c. Distortion d. Undercut
7. _________________ is a kind of weld defect which forms a groove in the parent metal along with the sides of the weld
bead.
a. Groove b. Hot tear c. Distortion d. Undercut
8. ________________________ reduces the thickness of the plate and also reduces the strength of the weld.
a. Groove b. Hot tear c. Distortion d. Undercut
9. ________________ is also known as solidification cracking state.
a. Groove b. Hot tear c. Distortion d. Undercut
10. ___________________ cracking is due to tearing of the grain boundaries of weld metal before complete solidification
has
taken place and metal is still in the plastic state.
a. Groove b. Solidification c. Distortion d. Undercut
TASK SHEET # 1
Direction: In answering this activity, you may attach additional sheets for your answers.
1. Find one example of fabricated welded structure in your home such as window grills, door grill, steel gate and
etc..
2. Draw it in a short bond paper.
Self-learning Instructional Material SY 2020-2021
3. Then identify the different type of defects present on the fabricated structure.
4. From the defect identified, list the causes and remedies of each defects.
Causes Remedies
1 1.
2 2.
3 3.
4 4.
5 5
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INFORMATION SHEET 2
Learning Outcome:
1. Identify the methods of striking an arc.
2. Prepare the safety gears needed for striking an arc.
A welding arc is maintained when the welding current is forced across a gap between the electrode tip and the base
metal. A welder must be able to strike and establish the correct arc easily and quickly.
What Is It
There are two general methods of striking the arc:
1. Scratching
2. Tapping
The scratching method is easier for beginners and when using an AC machine. The electrode is moved across the
plate inclined at an angle, as you would strike a match. As the electrode scratches the plate an arc is struck. When the
arc has formed, withdraw the electrode momentarily to form an excessively long arc, then return to normal arc length (see
figure 1).
In the tapping method, the electrode is moved downward to the base metal in a vertical direction. As soon as it
touches the metal it is withdrawn momentarily to form an excessively long arc, then returned to normal arc length (see
figure 2).
The principal difficulty encountered in striking the arc is "freezing," or when the electrode sticks or fuses to the
work. This is caused by the current melting the electrode tip and sticking it to the cold base metal before it is withdrawn
from contact. The extra high current drawn by the "short circuit" will soon overheat an electrode and melt it or the flux,
unless the circuit is broken. Giving the electrode holder a quick snap backward from the direction of travel will generally
free the electrode. If it does not, it will be necessary to open the circuit by releasing the electrode from the holder.
Warning: Never remove your face shield from your face if the electrode is frozen. Free the electrode with the shield in
front of your eyes, as it will "flash" when it comes loose. Tip: Brush your work free of dirt and scale before you strike an
arc.
Self-learning Instructional Material SY 2020-2021
SELF CHECK #2
Directions: Choose the correct answer from the series given for every item. Write the letter only. Use a separate
answer sheet.
1. 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
2. In the symbol E-6013; letter “E” stands for:
a. Electric b. Energy c. Electrode d. None of the above
3. Eyes can be protected during welding operations by using:
a. Gloves b. Leggings c. Goggles d. Apron
4. 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 these
5 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. Tapping Method b. Scratching Method c. All of these d. None of these
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OPERATION SHEET # 2
What I Can Do
Self-learning Instructional Material SY 2020-2021
What I have learned
Self-learning Instructional Material SY 2020-2021
Self check # 2 (OPERATION SHEET)
INFORMATION SHEET 3 9
Bead Formations:
Learning Outcome:
1. Identify the types of weld beads Prepare the safety gears needed for striking an arc.
2. Identify the different types of weaving motion beads.
3. Determine the appropriate electrodes to be used applicable for the specific bead and weld positions.
Type of beads
a. Stringer Bead- a straight forward bead in which
you either drag or push the electrode
across the joint with minimal side to side
movement.
b. Weave motion Beads - is a method for electrode
manipulation in joining metal to
achieve good weldment.
Self-learning Instructional Material SY 2020-2021
Different types of weave bead motion technique used in stick welding
1. Circular Motion- often used in flat position weld on butt,tee,and outside corner joints for build-up surfacing
operation.
2. Crescent Weave Motion- A half round bead formation in which formed a side to side semicircular
electrode movement.
3. Figure of eight motion weave – An electrode manipulation pattern where a continuous figure of number eight is
formed.
4. V- Pattern motion weave – a weave pattern commonly used in Hot pass and cap pass by forming V-motion.
5. Stringer Bead - a straight forward bead in which you either drag or push the electrode across the joint with
minimal side to side movement.
6. Square Pattern motion Bead – good for flat welds but they can also be used for vertical position. They can also
be used if there is a large gap to be filled.
7. J- pattern weave motion- works well on flat and horizontal positions.
8. T- pattern weave motion – works with fillet weld in vertical and overhead position. It can also be used for deep
grove welds for the hot pass.
9. Zigzag pattern motion weave – used as cover passes in flat and vertical positions.
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Self-learning Instructional Material SY 2020-2021
Self Check # 3
Task Sheet # 3
Direction: In answering this activity, you may attach additional sheets for your answers.
1. Different types of weave bead motion technique used in stick welding
2. What are the different types of weave bead motion technique used in stick welding?
3. Explain, what is the different between Stringer bead and weave motion beads?
4. Draw some weave bead technique used in stick welding in short bond paper.
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INFORMATION SHEET 4
Self-learning Instructional Material SY 2020-2021
Identify Standard Alphabet of Lines
Learning Outcome:
1. Select and Identify different alphabetical lines
2. Differentiate lines according to its uses
3. Application of lines according to job requirements
What’s In
This module contains information and suggested learning activities on Interpreting drawings and Symbols. It includes
instruction and procedure on how to Interpret Drawings and Symbols.
Completion of this module will help you to better understand the succeeding module which is the Contribution of
Quality System.
This module consists of three (3) objectives. Each learning objectives contains learning activities. Before you perform
the instruction, read carefully each task and answer the specified questions and activities provided. Your teacher will
assist you by monitoring on the internet or by calling on the phone of what you have acquired .
Upon completion of this module, report to your teacher by sending message or calling him/ her through phone. You
can also send your answer sheet on a given email add of your teacher.
What is it
Alphabet of Lines
The lines in the alphabet of lines are used to describe shape, size, hidden surfaces, interior detail and alternate
positions of parts. Each conveys a particular meaning on the drawing.
Each type of the line has a very precise symbolic correct meaning and usage in the alphabet of lines. It is also
essential whether you use the traditional drafting methods or ACAD. Line weight is the thickness of the line.
Construction lines and guide lines are very light, easily erased lines used to block the main lay out.
Source:
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Self-learning Instructional Material SY 2020-2021
There are several different types of lines used on a print and each has different meaning. To be able to
interpret a print, the reader should have knowledge of these lines. These lines are called alphabet of lines.
1. Object Line. Thick solid line used to show the visible shape of the object.
___________________________________________
2. Hidden Line. Broken line of medium thickness and used to show the edges and outlines not visible to
the eye.
- - - - - - - - - - - - - - - - - - - - - ----
3. Center Line. Fine, broken line made up of a series of short and long dashes alternately spaced. To show
the center of circles, arcs, and symmetrical objects and to aid in dimensioning the parts of the object.
__ _____ __ _____ __ ______ __
4. Extension Line. Fine lines that extend from the object with a slight break between and it is used to show
dimensioning points.
5. Dimension Line. Lines used to indicate the measurement of objects. It consists of three parts:
arrowheads, fine line, and number or measurement. The fine lines have the same thickness or weight as
the projection line. The arrowheads are short heavy strokes (called flares) placed at the extremities of
this fine line. The shape of an arrowhead is like the point of an ordinary pen. The number or figure is
usually positioned at the middle of the fine line and its axis is perpendicular to it.
6. Leader Line. Fine, straight line with an arrowhead or round solid dot at one end and usually drawn at an
angle. Points directly to a surface for the purpose of dimensioning or adding a note. A dot may be used
at the end of the straight line where reference is made to a surface area.
7. Cutting Plane Line. A thick broken line made up of a series of one long and two short dashes
alternately spaced. The arrowheads are placed at right angles to the cutting plane line. The purpose
of this line is to indicate where an imaginary cut is made through the object. The arrow points in the
direction in which the section should be viewed. Letters next to the arrowheads identify the section
in cases where more than one section is shown on the drawing. These lines are oriented vertically,
horizontally, or at the actual angle at which the part is drawn.
8. Section Lines. Series of fine lines-solid or solid and broken-arranged in specific patterns. They may be
shown either straight or curved. When shown straight, they are usually drawn at a 45 0 angle. It is used to
indicate the imaginary cut surface referred to by the cutting plane line. To represent various kinds of
materials.
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Self-learning Instructional Material SY 2020-2021
9. Chain Line. Heavy, broken line made up of a series of long and short dashes alternately spaced. It is
used to indicate the location and extent of a surface.
__________ ____ __________
10. Short Break Line. Heavy, irregular line drawn freehand used to show a short break to conserve space
on a drawing.
11. Long Break Line. Ruled, light line with freehand zigzags used to show a long break to conserve space
on a drawing.
12. Phantom Line. Light, broken line made up of a series of long and two short dashes used to show
alternate positions of a part; to show relationship of existing part to new part; and to show machined
surfaces.
__________ __ __ ________ __ __ __________
Self Check # 4
Matching type:
Directions: Match the name of the Alphabet of Lines with the correct pictures. Write the letter of your answer.
Self-learning Instructional Material SY 2020-2021
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Task Sheet # 4
Directions: Draw an object that you found in your environment or in your home. Apply it using the different
alphabetical lines you know from the topic that you have already read. Draw it in a short bond paper.
Self-learning Instructional Material SY 2020-2021
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Information sheet # 1 Information sheet # 2 Information sheet # 3
Self Check # 1 Self Check # 2 Self Check # 3
1. d 1. b 1. d
2. a 2. c 2. i
3. c 3. c 3. b
4. a 4. b 4. h
5. a 5. a 5. e
6.c 6. f
7. d. 7. g
8. a 8. c
9. b 9. a
10. b
Information sheet # 4
Self Check # 4
1. b
2. a
3. d
4. c
5. e
6. g
7.f
8. h
Prepared by:
JOSE N. GLAMAYO
TVL-SMAW TEACHER II
Cell #:09159777724/09108579431
Checked by:
AURORA N. PARAN, Ed.D.
HT-VI, HEAD, SHS
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Approved by:
ZOSIMO R. CABUG-OS, Ph.D.
PRINCIPAL IV
