Teacher-Made Learner's Home Task: Essentials of Welding

Teacher-Made Learner’s Home Task
School: ____________________________________ Date: __________________________________

Grade/Section: ____________________Subject Area/s: Shielded Metal Arc Welding (SMAW)
I. MELC/ CG : Essentials Of Welding Code: TLE_ IAAW12G-Ia-I
II. Objective/s:
Knowledge: Identify the 5 essentials of welding
Skills: write possible problems on essentials of welding
Values/Attitude: Shows diligence in studying their lessons
III. Subject Matter: Essentials Of Welding

IV. References:
SMAW 11-12 Learner’s Module: Welding Carbon Steel Plates and Pipes Using SMAW, pp.11-20
Guidelines for Shielded Metal Arc Welding
Philippine Welders and Fitters Society
Books.google.com.ph
Weldinghelmetpros.com
IV. Procedure:
A. Readings
ESSENTIALS OF WELDING
Weld quality and consistency can only be maintained with respect to the five essentials. The five essentials of
welding include the use of correct electrode size, current, arc length or voltage, travel speed and electrode
angles. Once the welder masters the ability to consistently maintain the five essentials, the ability to control
the puddle will follow. Here are the five essentials of welding.
Electrode size- electrodes for shielded metal arc welding range in diameter from 3/32 to 3/16 of an inch.
You may also come across some ¼ inch electrodes. They are commonly found in 9, 14 and 18-inch lengths.
Choosing the correct electrode size involves many factors. If a smaller recommend electrode is used welding
time and heat to the joint will increase. It can result in increased costs, heat affected zone, cracking or
distortion.
Larger electrode can cause melt-through and can be difficult to control in out of position joints. Poor
appearance and possible defects can result. The welding procedure designates the correct electrode size,
generally based on metal type and thickness. However, if no procedure or instruction is available the welder
will have to choose the correct electrode size.
Current- measured in amperes, or amps. Each type of electrode has recommended amperage ranges for
optimum performance. The correct current setting is vital for maintaining consistency in weld quality. If the
current is too high, the electrode melts too fast, and the molten pool is larger and irregular. If the current is
too high when welding single vee-groove, it might blow holes through the joint and cause large molten metal
droplets to fall out of the groove.
If the current is too low, there is not enough heat to melt the base metal. The molten pool will be
too small, piles up, and looks irregular. Poor penetration and incomplete fusion in the joint can result.
Arc Length- the distance from the tip of the electrode core wire to the weld puddle. Arc length can be
deceiving because the core wire is recessed inside a cup that forms at the tip of the electrode. Arc length is
very important for weld puddle control. Correct arc length will cause the deposit to be neat of even ripple and
of good penetration. Too long arc length will cause the deposit to coarse rippled and flatter than normal with
an increase in spatter. When welding a root pass in an open root vee groove, the keyhole can grow too large
and loose of weld control can result.
Too short an arc will cause deposited to be narrow, uneven and irregular rippled and with poor fusion.
The arc length reduces the voltage and increase the amperage slightly but the electrode may stick to the
work. When welding root passes, too short an arc length often results in loss of the keyhole.
Travel Speed- is the rate at which the electrode moves along the work. The key to correct
travel speed is reading the weld puddle, because the weld puddle is a liquid version of the
weld bead. Incorrect travel speed is a common mistake. Sometimes travel speed is the only
condition a welder may need to change. Travelling too fast causes the puddle to freeze too
quickly. Because of this, impurities and gases can become entrapped, making the bead face
narrow with pointing ripple.
Incomplete penetration due to loss of the keyhole in root pass is possible. Travelling too slow will
cause the puddle to be large, with pile-up, and a straight ripple pattern. For out of position welding, slow
travel speed can cause the puddle to drip out the joint.
Travelling too slow produces a wide convex bead.
Slow travel speed will create too much weld deposit.
This can result in insufficient penetration.
It can also focus the heat into the puddle and not into the base material
Excessively fast travel speeds create a concave or a recessed weld.
Electrode angle- is used to control the shape of the weld puddle and the amount of
penetration. The travel angle is the angle between the joint and the electrode along the axis
of the weld. One of the most essential is the use of the correct angles. For fillet weld and
groove weld, correct electrode angles are vital for preventing undercut and inadequate fill.
When depositing a fillet weld the electrode should be held so that it bisects the angle
between the plates and is perpendicular to the line of the weld. On groove weld, the
technique is much the same; although varying slightly with multiple pass welding.
There are two teams to specify electrode angles. These are travel angle and work angles. The travel
angle applies to the position the electrode make with a reference perpendicular to the axis of the weld in
plane of the weld axis. It can be either a drag angle or a push angle. A drag angle is when the electrode is
pointing backward, meaning the welder’s hand and electrode holder proceeds the puddle. A push angle
is when electrode is pointing just the opposite of the drag.
The work angle is the position the electrode makes with reference to the surface of the plate on a
plane perpendicular to the weld axis. On butt joint the work angle is usually 90 degrees to the surface of
the plate. To some degree, you can correct for an improper condition by varying the essential variables.
It is better though to have all conditions as correct as possible.
B. Exercises for skill subjects / Analysis questions using HOTS for content subjects
Exercise 1: Identify the pictures below of the essentials of welding. Write your answer on the
separate sheet of paper.
2.
1.
4.
3.
5. 6.
Exercise 2: Answer the questions base on the pictures found in exercise 1.

1. What is the cause of poor penetration during welding?
2. How do you classify the essentials of welding?
3. Why do we need to know the essence of essentials of welding?
Multiple Choice: Choose the correct answer and write the letter that corresponds to your choice on the
answer sheet provided.
1. Which of the following essentials of welding applies to the position the electrode makes with
a reference perpendicular to the axis of the weld in plane of the weld axis.
A. Travel angles B. Work angles C. drag angle D. Butt angle
2. It is electrode that pointing just the opposite of the drag.
A. Travel angles B. Work angles C. drag angle D. Butt angle
3. Which of these can cause melt-through and can be difficult to control in out of position
joints?
A. Larger angle B. Shorter angle C. less angle D. Greater angle
4. What do you call the distance from the tip of the electrode core wire to the weld puddle?
A. Arc length B. Travel speed C. Current D. Electrode size
5. It is used to control the shape of the weld puddle and the amount of penetration.
A. Correct Arc length B. Correct Travel speed C. Correct Current D. Correct Electrode angle
C. Assessment/Application
I. Directions: Write the possible problems occur during welding.
II. Directions: Read each statement below carefully. Write TRUE if the statement is correct and
FALSE if the statement is not correct.
1. Using a larger electrode diameter can cause melt-through/burn-through .____
2. Travelling too fast will make the bead face narrow with pointing ripple. _____
3. If the current is too low, the electrode melts too fast. ______
4. Quality or sound weld is the result of the correct current, constant voltage, travel speed,
electrode angle and correct electrode size. ______
5. In fillet weld, electrode angle is not necessary for preventing undercut and underfill. ___
Prepared by: FLORDELIZA P. EULDAN
Teacher
Verified by: ARLENE D. BUOT, Ed. D.
School Head

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What are the five essentials of welding?

What factors should be considered when choosing an electrode size?

Teacher-Made Learner’s Home Task

School: __ Date:

I. MELC/ CG : Essentials Of Welding Code: TLE_ IAAW12G-Ia-I

III. Subject Matter: Essentials Of Welding

Exercise 2: Answer the questions base on the pictures found in exercise 1.

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