6 Prepare Weld Materials

COMPETENCY BASED LEARNING MATERIAL
Sector:
METALS AND ENGINEERING SECTOR
Qualification:
SMAW NC II
Unit of Competency:
PREPARE WELD MATERIALS
Module Title:
PREPARING WELD MATERIALS
Technical Education and Skills Development Authority

PROVINCIAL TRAINING CENTER
Gattaran, Cagayan
METALS AND ENGINEERING
INDUSTRY SECTOR
NATIONAL CERTIFICATE LEVEL II
QUALIFICATION LEVEL
COMPETENCY-BASED LEARNING MATERIALS
No. Unit of Competency Module Title Code
Basic Competencies
1 Participate in Workplace Participating in Workplace
Communication Communication
2 Work in a Team Environment Working in a Team Environment
3 Practice Career Professionalism Practicing Career Professionalism
4 Practice Occupational Health and Practicing Occupational Health and
Safety Procedures Safety Procedures
Common competencies
1 Apply Safety Practices Applying Safety Practices
2 Interpret Drawings and Sketches Interpreting Drawings and Sketches
3 Perform Industry Calculations Performing Industry Calculations
4 Contribute to Quality System Contributing to Quality System
5 Use of Hand Tools Using Hand Tools
6 Prepare Weld Materials Preparing Weld Materials
7 Set-up Welding Equipment Setting-up Welding Equipment
8 Fit-up Weld Materials Fitting-up Weld Materials
9 Repair Welds Repairing Welds
Core Competencies
1 Weld Carbon Steel Plates using SMAW 1.1 Perform Fillet Weld on Carbon Steel
Plates using SMAW
1.2 Perform Groove Welding on Carbon
Steel Plates using SMAW
2 Weld Carbon Steel Pipes using SMAW 2.1 Perform Groove Welding on Carbon
Steel Pipes using GSMAW
Sector: Date Developed: Document No.:

Metals and Engineering 1041522SMAW061
April 15, 2022 Revision No
Course Title:
Shielded Metal Arc Welding NCI
Developed by: Page 1 of 81
PREPARE WELDING MATERIALS Robin M. Concordia
SMAW Trainer
HOW TO USE THIS COMPETENCY BASED LEARNING MATERIAL
Welcome to the Module; Preparing Weld Materials. This module contains training materials and
activities for you to complete.
The unit of competency “Preparing Weld Materials" covers the skills, knowledge, and attitudes in safety
practices applied in the workplace. It is one of the Common Competencies of Shielded Metal Arc Welding
National Certificate Level I (SMAW NC I).
You are required to go through a series of learning activities in order to complete each learning outcome
of the module. In each learning outcome there are Information Sheets, Resource Sheets and Reference
Materials for further reading to help you better understand the required activities. Follow these activities on
your own and answer the self-check at the end of each learning outcome. Get the answer key from your
instructor and check your work honestly. If you have questions, please don’t hesitate to ask your facilitator for
assistance.
Recognition of Prior Learning (RPL)
You may already have some or most of the knowledge and skills covered in this module because you
have:
 Been working for some time
 Already completed training in this area.
If you can demonstrate to your trainer that you are competent in a particular skill or skills, talk to your
trainer about having them formally recognized so you won't have to do the same training again.
If you have qualification or Certificates of Competency from previous training, show them to your trainer.
If the skills you acquired are still relevant to this module, they may become part of the evidence you can
present for RPL.
At the end of this learning material is a Learner’s Diary, use this diary to record important dates, jobs
undertaken and other workplace events that will assist you in providing further details to your trainer or
assessors. A Record of Achievement is also provided for your trainer to complete once you completed the
module.
This learning material was prepared to help you achieve the required competency in preparing weld
materials. This will be the source of information for you to acquire the knowledge and skills in this particular
trade independently and at your own pace with minimum supervision or help from your instructor.
In doing the activities to complete the requirements of this module, please be guided by the following:
 Talk to your trainer and agree on how you will both organize the training under this module. Read
through the module carefully. It is divided into sections which cover all the skills and knowledge you
need to successfully complete.
 Work through all information and complete the activities in each section. Read the information
sheets and complete the self-check. Suggested references are included to supplement the materials
provided in this module.

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 Most probably your trainer will also be your supervisor or manager. He/she is there to support you
and show you the correct way to do things. Ask for help.

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SMAW Trainer
 Your trainer will tell you about the important things you need to consider when you are completing
the activities and it is important that you listen and take notes.
 You will be given plenty of opportunities to ask questions and practice on the job. Make sure you
practice your new skills during regular work shifts. This way you will improve both your speed and
memory and also your confidence.
 Talk to more experienced work mates and ask for their guidance.
 Use self-check questions at the end of each section to test your own progress.
 When you are ready, ask your trainer to watch you perform the activities outlined in this module.
 As you work through the activities, ask for written feedback on your progress. Your trainer keeps
feedback/pre-assessment reports for this reason. When you have successfully completed each
element, ask your trainer to mark on the reports that you are ready for assessment.
 When you have completed this learning material and feel confident that you have had sufficient
knowledge and skills, your trainer will arrange an appointment with a registered assessor to assess
you. The results of your assessment will be recorded in your Competency Achievement Record.

Course Title:
SMAW Trainer
MODULES OF INSTRUCTION
UNIT OF COMPETENCY Prepare Weld Materials
MODULE TITLE Preparing Weld Materials
MODULE DESCRIPTOR
This module covers knowledge, skills, and attitude required in preparing weld joints.
NOMINAL DURATION: 5 hours
LEARNING OUTCOMES:
At the end of this module you MUST be able to:
1. Set-up cutting equipment

2. Cut and prepare edge of materials
3. Clean surfaces and edges
4. Prepare welding consumables
5. Prepare welding safety and protective equipment

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SMAW Trainer
MODULE CONTENT
Module Title: Preparing Weld Materials
Learning Outcome Learning Content Progress Check Training Page

No. Duration No.
1. Set-up cutting 1. Parts and function of Self-check

equipment cutting equipment
2. Set up cutting Self -check
equipment
3. Lighting and adjusting of Self -check
flames
2. Cut and prepare 1. Cutting operation Self -check
edge of materials procedure
2. Cutting materials with Self-check
different process
3. Clean surfaces and 1. Procedure and Self-check
edges techniques of preparing
plates and pipe edges for
welding
2. Equipment and tools for Self-check
preparing plates and
pipes edges
3. Safe working practices Self-check
4. Prepare welding 1. Consumable materials Self-check

consumables specifications
2. Safe working procedures Self-check
in preparing
consumables
5. Prepare welding 1. Procedures and Self-check
safety and techniques in checking
protective protective equipment
equipment 2. Safe working practices Self-check
and handling of
protective equipment

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SMAW Trainer
COMPETENCY SUMMARY
Qualification : SMAW NC II
Unit of Competency : Prepare Weld Materials
Module Title: Preparing Weld Materials
Introduction
This module covers the knowledge, skills, and attitude required in preparing weld materials.
You need to complete and pass self-check of this module before you can perform higher level of
competencies. Practices in this module will help you identify the parts and accessories of the cutting
equipment, set-up cutting equipment, cut and prepare edge of materials, clean surfaces and edges, prepare
consumables, and prepare welding safety and protective equipment. Desirable values and attitude must also
be taken into consideration.
This module consists of three learning outcomes. Each learning outcome contains learning activities
for both knowledge and skills, supported with information sheets, activity sheet, job sheets, operation sheets
and self-checks, gathered from different sources. Before you perform the manual exercises, read the
information/activity/job/operation sheets mentioned in the special instruction column and answer the self-
check for confirmation that you are equipped with the knowledge necessary to perform the skills portion of the
particular learning outcome with your instructor.
Upon completion of this module, you have to submit yourself to your instructor for assessment. You
will be given a Certificate of Completion as a proof that you have met the standard requirements (Knowledge &
Skill) for this module. The assessment could be made using different methods, as prescribed in the
competency standard.
Learning Outcomes:
Upon completion of the module, the trainees/students should be able:
2. Cut and prepare edge of materials
3. Clean surfaces and edges
4. Prepare welding consumables
5. Prepare welding safety and protective equipment
Assessment Criteria:
1. Cutting equipment should be operational and should conform to acceptable OH&S standards.
2. Cutting equipment fittings, connection and power source are checked in accordance with
workplace procedures.
3. Materials are cut to specified dimension/specifications.
4. Tasks are performed in accordance with company/industry requirement and safety
procedures.
5. Surfaces are cleaned to required specifications.
6. Task performed in accordance with company or industry requirements and safety procedures.
7. Consumables, materials, specified and quantity determined in accordance with job
requirements.
8. Correct materials selected in accordance with job requirements.
9. Personal protective equipment should conform to OH&S requirement and standards.

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10. Welding safety and protective equipment are checked in accordance with safety procedure.

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DEFINITIONS OF TERMS:
a. Flame Cutting – A process of cutting ferrous metals by removing some of the metal as does a
common saw.
b. Kerf – Cut made by the cutting torch
c. Drag Line – A condition where the most distant portion of the cutting stream lags behind the
stream nearest the cutting tip.
d. Slag – The porous oxidized residue left after oxyacetylene cutting.
e. Purging – The process of removing air in the hoses or gas line with the appropriate gas prior to
welding or cutting.
f. Cracking the valve – Blow out any dirt lodged in the valve opening of the cylinder.
g. Backfire – Flame goes out with a loud snap or pop.
h. Flashback – Flame burns back inside of the tip, hose or regulator.
i. Flashback Arrestor – A device that does the job of a reverse flow valve and it will stop the flame of
flashback.
j. Manifold System –A brazed assembly of pipes that delivers gas from several cylinders into one supply
pipe. The pipe distributes gas to several workstations or locations.

Course Title:
SMAW Trainer
LEARNING OUTCOME SUMMARY
Qualification : SMAW NCI
Module Title : Preparing Weld Materials
Learning Outcome #1 : Set-up Cutting Equipment
CONTENTS:
1. Parts and function of Oxy-acetylene cutting equipment
2. Procedures in setting-up cutting equipment
3. Procedure in checking cutting equipment functionality
1. Cutting equipment should be operational and should conform to acceptable OH&S standards.
2. Cutting equipment fittings, connection and power source are checked in accordance with
workplace procedures.
Resources:
Students/Trainees must be provided with the following:
Tools Equipment Supplies & Materials

CBLM in Setting-up cutting
Welding tools Oxy-acetylene outfit
equipment
PPE Other related learning
materials
Evaluation Method:
 Written Test
 Demonstration
 Direct observation
 Interview

Course Title:
SMAW Trainer
Learning Experience
LEARNING OUTCOME # 1:Set-up Cutting Equipment
Learning Activities Special Instructions
1. Read Information Sheet No. 6.1- If you have some problem on the content of the information
1Parts and function of cutting sheet don’t hesitate to approach your facilitator.
equipment
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 Self-Check No. 6.1-1 Compare your answer to the answer key 6.1-1. If 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.
3. Read Operation Sheet No. 6.1-2 Set If you have some problem on the content of the information
up cutting equipment sheet don’t hesitate to approach your facilitator.

the next information sheet. If not, review the information
5. Perform Operation Sheet on the Read the operation sheet and review the performance criteria
Procedures in Cutting Equipment for this activity
Functionality
If you have some problem on the content don’t hesitate to
approach your facilitator.
If you feel that you are now ready to perform the task, inform
your facilitator about you intention.
6. Inspect the output of this activity Use the performance criteria to evaluate your own output.
Inform your facilitator to check your evaluation report.
If you have satisfied the standard, you can now proceed to

the next activity.

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SMAW Trainer
Information Sheet No. 6.1-1
Parts and Functions of Oxy-acetylene Cutting Outfit
Objectives:
At the end of the lesson, the trainees are expected to;
1. Identify the parts and functions of the oxy-acetylene outfit.
The flame cutting process, used on metals containing iron, is the result of a chemical reaction.
Oxygen has a chemical attraction to ferrous metals when they are heated above the kindling
temperature. Therefore, during the cutting process, the welder always uses more oxygen than fuel gas,
which is usually acetylene. Exposed to the extra oxygen, the red hot iron is oxidized. When iron burns
up, it leaves ashes or slag. Also, the energy of the cutting oxygen stream washes away as much as
one-third of the molten metal.
Characteristics of oxyacetylene cutting
A. Oxyacetylene cutting units are readily portable and can be taken to the work as opposed to having
to bring the work to the cutting equipment.
B. Oxyacetylene cutting equipment is relatively inexpensive when compared to the cost of other
cutting procedures.
C. Oxyacetylene cutting can be accomplished quickly and is probably the fastest method of cutting
thicker metals or cutting regular or odd shapes.
D. Oxyacetylene cutting, when properly executed, delivers a high – quality cut.
E. Oxy-acetylene cutting is often done manually but can be adapted to automatic process
Parts of Oxy-acetylene Cutting/Welding Outfit
1. Fuel Gas Cylinder. Portable container

used to store fuel gases like acetylene.
2. Oxygen Gas Cylinder. Seamless,

portable container used to store
oxygen. Oxygen is stored in
cylinders at a pressure of
about 2200 psig.
3. Pressure Regulator and Gauges.

A device used to reduce pressure
at which oxygen or fuel
gas is delivered.

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Types of Regulators
a. Two-stage Regulator. A two-stage regulator will maintain nearly constant outlet
pressures and flows during long periods of operation. This is best suited for
continuous operation.
b. Single-stage Regulator. Provides greater flow than a comparable two-stage regulator
because it places fewer restrictions on the gas flow.
Parts of Pressure Regulator

a. High Pressure Gauge – indicates cylinder pressure
b. Low Pressure Gauge – indicates working pressure
c. Regulator Body – gas reservoir before flowing to the hose going to the torch
d. Adjusting Screw – controls the flow of gases from high pressure gauge to working
gauge
e. Cylinder Fitting – used to connect the regulators to the valve cylinders.
4. Hoses and Fittings. A hose is a flexible tube used to convey gases from a pressure regulator to a
welding torch. Oxygen hose is green while the fuel gas hose is red. Both single and dual (Siamese)
hoses are available.
A fitting is used to connect the hose to the regulator or torch. Oxygen hose nuts have right-
hand thread. Fuel hose nuts have left-hand thread, and a groove machined around the nut for
identification.
5. Check Valves. A valve that allows the flow of gas in only one direction. This is used to prevent the
reverse flow of gases through the torch, hoses, and/or regulators.
6. Flashback Arrestor. A device used to prevent the flow of a burning fuel gas and oxygen mixture
from the torch back into the hoses, regulators and cylinders. It is designed to eliminate explosion
in the regulator or cylinder.
7. Torches. Device use to control and mix the fuel gas and oxygen and to direct the gas flame to the
work.
1. Welding Torch. This controls and mixes fuel gas and oxygen. It is also used to direct the
gas flame to the welding, brazing or soldering work areas.
2. Cutting Torch. This torch has an additional oxygen passage built into it. This passage
carries the oxygen used to cut or oxidize the metal.

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Self – Check No. 6.1-1
Parts and Functions of Oxy-acetylene Cutting Outfit
Multiple Choice:
Direction: Read and analyze the statement carefully. Choose the best answer and write the
letter only in your answer sheet.
1. This serves as storage for fuel gases and oxygen.

a. tank
b. reservoir
c. container
d. cylinder tank
2. Fuel gas and oxygen gas mixed together at the __________ of the torch.
a. gas hose
b. blow pipe
c. cutting tip
d. preheating gas tube
3. High pressure gauge of the pressure regulator indicates

a. working pressure
b. flow of gas to the hose
c. pressure of the cylinder
d. working pressure and gas flow
4. Oxygen hose colored green with nuts threaded as

a. fine thread
b. course thread
c. left-hand thread
d. right-hand thread
5. Valve that allows the flow of gas in only one direction used to prevent the reverse flow of gases
through the torch, hoses, and/or regulators
a. check valve
b. oxygen valve
c. fuel gas valve
d. flashback arrestor

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Answer Key No. 6.1.1
1. d
2. b
3. c
4. d
5. a

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Parts and Functions of the Cutting Torch
Objectives:
1. Identify the parts and functions of the cutting torch.
Oxy-fuel gas cutting and welding equipment is essentially the same. The main differences in
the cutting and welding outfits are in the oxygen regulator and the torch. A larger volume and
pressure of oxygen may be needed for cutting heavy metal. A pressure regulator with a larger volume
capacity and high pressure indications is used.
Parts of an Oxy-acetylene Cutting Torch
a. Torch Valve. Control the flow of oxygen and fuel gases.
b. Torch Tip. Part of the torch where fuel gas and oxygen are ignited.
c. Tip Nut. Large threaded nut used to hold the torch tip in the cutting torch head.
d. Cutting Oxygen Tube. Carries the oxygen used to cut, or oxidize the metal.
e. Preheating Gases Tube. Carries the oxygen and fuel gases from the mixing chamber
down to the cutting tip orifice holes.
f. Oxygen Valve. Used to regulate the flame into neutral, oxidizing or carburizing flame.
g. Torch Body and Valve. Also called as the blowpipe. This is the mixing chamber of the
torch.
h. Cutting Oxygen Lever. Used to release oxygen gas during cutting operation.

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Cutting Tip Data Chart
Metal Regular Pressure (PSI)

Thickness Tip size Acetylene Other Fuel Oxygen
Gases
1/8 “ 000 6 10-11 23
3/16” 00 6 10-11 23
1/4 “ 0 7 10-11 33
3/8 “ 0 7 10-11 40
1/2 “ 1 7 10-11 40
5/8 “ 1 7 10-11 45
3/4 “ 2 7 10-11 40
1“ 2 7 10-11 45
1 1/4 “ 2 7 10-11 55
1 1/2 “ 3 8 10-11 50
2” 3 8 10-11 55
1 1/2 “ 4 8 10-11 45
3” 4 8 10-11 50
4“ 4 8 60
5“ 5 9 60
6“ 5 9 70
8“ 5 9 80

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Parts and Functions of the Cutting Torch
Multiple Choice:
Direction: Read and analyze the statement carefully. Choose the best answer and write the
1. Parts of the cutting torch that controls the flow of oxygen and fuel gases.
a. torch valve
b. oxygen valve
c. cutting oxygen tube
2. This is the mixing chamber of the torch.

a. torch valve
b. preheating gas tube
c. cutting oxygen lever
d. torch body and valve or blowpipe
3. Cutting oxygen lever is intended to operate cutting process for the purpose. It is used to release
oxygen gas during cutting operation.
a. regulate gases
b. control the flow of gases
c. release oxygen gases to cut
d. carries oxygen gas to oxidize metal
4. What would be the working pressure of fuel gas in cutting ¼” thick materials?
a. 6 psi
b. 7 psi
c. 8 psi
d. 9 psi
5. What is the recommended size of cutting tip to cut ½” thick plates?

a. 00
b. 1
c. 2
d. 3

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Answer Key No. 6.1.2
1. a
2. d
3. c
4. b
5. b

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Operation Sheet No. 6.1-3
Set Up Oxy-acetylene Outfit
Objectives:
1. Set up oxy-acetylene cutting outfit.
Proper assembly, care, and security of the oxy-fuel gas welding and cutting outfit is necessary
for its safe and effective use. Care must be taken when assembling the various threaded fittings. When
tightened, the fittings must not leak. The fittings are generally made from soft metal like brass and
over tightening of the fittings may easily damage its thread.
Set – up Oxy-acetylene Welding Outfit
1. Set the oxygen and acetylene cylinder

side by side in an upright position.
The tanks should then be chained
or otherwise held in place.
2. Unscrew the valve protection caps on

top of the cylinders. Put the caps
in a safe place.

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3. Crack the valve. Dust or grit that may be
accumulated in the valve opening and should
be cleared out by cracking the valve.
Be sure the regulator inlet
connections are clean.
4. Attach the regulator with the right-hand

thread connection to the oxygen and the
left-hand thread connection to the acetylene.
Note: Once the regulators have been screwed

onto the tank outlets by hand, tighten
them with a regulator nut wrench.
Tighten firmly but do not use
too much force.
5. Turned counter-clockwise the regulator

adjusting handle. The oxygen cylinder valve is
opened first, very slowly, counter-clockwise
until the pressure needle on the gauge
reaches its maximum. Opening the
valve slowly guards against rupturing
the regulator diaphragm. The
same procedure is used for
opening the acetylene cylinder,
except that the valve on the
cylinder should never be
opened more than one
and one-half turns.
6. Attach the hoses to the regulators.

The green hose has right-hand
thread for oxygen, and the red
hose has left-hand thread
for acetylene.

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SMAW Trainer
7. On the oxygen tank, turn the regulator
adjusting screw clockwise until 5 psi
registers on the line pressure gauge.
If the hose is new, purging should be
applied to get rid of the talcum powder
inside. Adjust the regulator until no gas
comes out of the hose. Do the same
things for the acetylene hose.
Caution: Acetylene will burn,

so keep it away from open flames.
8. Connect the hose to the torch. Torch valves are usually marked OXY and ACET.
Note:
Since all the connections are now
under gas pressure, check all
possible areas for gas leaks by
using soapy water. Any leaking
connections should be tightened
before lighting the torch.
Note:
Turn off the cutting or welding torch needle valves.
Attach the cutting tip. Faulty tip seats can cause flashback,
as well as poorly operating the torch valves.

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Observation Checklist
Set Up Oxy-acetylene Outfit
CRITERIA PERFORMANCE
YES NO
1. Tank cylinders are held in an upright position.
2. Crack the valve
3. Perform purging
4. Working pressure of the regulator is set to the required pressure.
5. No sign of leak is observed in all fittings of the cutting outfit.
Feedback to the candidate
Candidate’s overall performance:
Satisfactory Not Satisfactory
Trainee’s Signature: Date:

Trainer’s Signature: Date:

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Lighting and Adjusting the Flame
Objectives:
1. Perform lighting and adjusting flames of the oxy-acetylene outfit.
After the oxy-acetylene cutting outfit has been set properly, carefully light and adjust the
cutting torch to the required cutting flame.
Open the acetylene and oxygen valves 1/4 – 1/2 turn before setting the working pressures.
The cutting torch oxygen valve lever should also be open while the oxygen cutting pressure is set. After
setting the working pressures for oxygen and acetylene, close the torch valves and release the oxygen
cutting lever.
1. Open the acetylene torch valve slightly (approximately 1/16 turn).
2. Light the acetylene at the torch tip, using a spark lighter. All flames should light at the time. If all
the flames do not light, shut down the torch and clean the dirty orifices.
Note: When lighting the torch, always position the tip of the cutting torch facing downward.

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3. Open the acetylene torch valve until flame becomes turbulent (rough) about ¾” to 1” ( 19-25 mm)
from the end of the tip. Adjust the acetylene so the flame no longer smokes or releases soot.
4. Turn on the oxygen torch valve slowly after the acetylene is regulated. Adjust the oxygen torch
valve until a neutral flame is obtained.
5. Open the cutting oxygen valve (lever). The preheating flames should remain neutral

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Shutting Down an Oxy-acetylene Welding Outfit
The flame must be turned off whenever the oxy-acetylene torch is not in your hand. The flame
is turned off by closing the acetylene torch valve and then the oxygen torch valve.
The welding outfit should be shut down when not in use, following this procedure:
1. Turn off the flame. First, turn off the oxygen valve. Then, turn off the oxygen torch valve followed
by the acetylene torch valve.
2. Completely close the acetylene and oxygen cylinder valves.
3. Open the oxygen and acetylene torch valves. This allows all the gases in the system to escape.
4. Close the torch valves after the high and low pressure gauges read zero.
5. Turn the adjusting screws on both regulators counter clockwise until they feel loose.

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YES NO
1. What is the recommended igniter to light the cutting torch?
2. Tip of the cutting torch is properly positioned before lighting the
torch.
3. Flame of the cutting torch is adjusted to oxidizing flame,
carburizing flame and neutral flame.
4. Shutting down the torch is properly observed.


Course Title:
SMAW Trainer
Qualification : SMAW NC II
Learning Outcome #2 : Cut and Prepare Edges of Materials
CONTENTS:
1. Cutting operation procedure

2. Cutting materials with different cutting processes.
1. Materials are cut to specified dimension/specifications.

2. Tasks are performed in accordance with company/industry requirement and safety
procedures.
Resources:

CBLM in Setting-up cutting
Welding tools Oxy-acetylene outfit
equipment
materials
Evaluation Method:
 Written Test
 Demonstration
 Interview

Course Title:
SMAW Trainer
Learning Experience
LEARNING OUTCOME # 2: Cut and Prepare Edges of Materials
1. Read Operation Sheet No. 6.2-1 If you have some problem on the content of the information
Cutting operation procedures sheet don’t hesitate to approach your facilitator.

the information sheet, you can now answer self check
the next information sheet. If not review the information sheet
and go over the self-check again.
3. Read Information Sheet No. 6.2-2 If you have some problem on the content of the information
Elements of poor and good cuts sheet don’t hesitate to approach your facilitator.

the information sheet, you can now answer self check
the next information sheet. If not review the information sheet
and go over the self-check again.

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Cutting Processes
Objectives:
1. Familiarized with other cutting process.
A. Gouging
In gouging, the metal is not

cut into two pieces. Instead, a
groove is cut in the metal to a
certain depth, depending
on the job.
B. Tractor-type Cutting
Tractor-type cutting machines almost always require set-up, alignment, and adjustment by an
operator. Operate on tracks mostly confined to horizontal cutting, but some models have magnetic
tracks that permit them to cut in vertical or overhead position. Powered by a motor-driven carriage
with governor-controlled speed. Many models have provisions for mounting two torches. Used mostly
for making square or bevelled cuts, but can be modified with a radius rod to cut circles.

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C. Hand-guided Cutting
Vary in design from a single wheel to three wheels with attachments for cutting straight lines,
bevels, circles, and irregular shapes. Adjustable to many steel forms including rod and pipe, and can
be used to cut horizontally or vertically. Are controlled by operators Who control speed and direction of
cutting torch which is centred in front of or beside a drive wheel
D. Pipe Bevelling
Designed specifically for cutting beveled angles, T's and Y's, and other connecting shapes for pipe. May
be manually operated or motorized. Basic design is a split horseshoe that fits the inside or outside
contour of the pipe and is then clamped into position for cutting. Torch holders are designed with
easy-to-read protractors for precise control of cutting angle.

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E. Shape-cutting
Usually designed for specific job requirements where the cutting of multiple identical shapes
contributes to high productivity. They function as tracing machines which use a photocell or electric
eye to trace a pattern or magnetic devices to follow a metal template. Have gas torch control functions
operated from a terminal or panel to provide precise operator control. Machines may be numerically
programmed with a punched tape fed into a master control unit, or controlled digitally with solid state
devices on a push-button control panel

Course Title:
SMAW Trainer
Cutting Processes
Multiple Choice:
Direction: Read and analyze the statement carefully, choose the best answer and write the
1. This cutting process operates on tracks mostly confined to horizontal cutting.

a. Gouging
b. Pipe bevelling
c. Shape cutting
d. Tractor-type cutting
2. During this cutting process, the material is not cut into two pieces but instead a groove is cut to a
certain depth.
a. Gouging
b. Pipe bevelling
c. Shape cutting
3. The following are the characteristics of the pipe-bevelling machines except,

a. May be manually operated or motorized
b. Designed specifically for cutting angles, T’s and Y’s
c. Torch holders are designed with easy-to-read protractors
d. Use a photocell or electric eye to trace a pattern or magnetic devices to follow a metal
template.
4. Adjusted to many steel forms including rod and pipe and can be used to cut horizontally or
vertically.
a. Pipe bevelling
b. Shape cutting
c. Tractor-type cutting
d. Hand-guided cutting
5. Have gas torch control functions operated from a terminal or panel to provide precise operator
control.
a. Pipe bevelling
b. Shape cutting

Course Title:
SMAW Trainer
Answer Key No. 6.2-1
1. d
2. a
3. d
4. d
5. b

Course Title:
SMAW Trainer
Elements of Poor and Good Cuts
Objectives:
1. Identify the causes of good and poor cuts of the materials
Cutting process using oxy-acetylene gas cutting requires more skill to produce quality cuts.
Several factors must be considered to prevent poor cuts and focus to the factors producing good cuts.
Major Causes of Poor Cuts
1. Improper tip selection

2. Speed too fast and too slow
3. Tip and torch angles incorrect
4. Preheat flame too far from workpiece
5. Working pressure incorrectly set
6. Oxygen cutting lever not fully depressed
7. Incorrect flame adjustment
8. Cutting tip orifices clogged with slag or dirt
Elements of a Good Cut
1. Edge is square
2. Drag lines are essentially vertical
3. No adhering slag at the bottom edge of the cut
Reasons for Poor Cuts
1. Preheat flames were not hot enough for this cut with the result that the cutting speed was
too slow, causing bad gouging at the bottom

Course Title:
SMAW Trainer
2. Preheat flames were too hot with result that the top surface has melted over the cut edge
is irregular and there is an excessive amount of adhering slag.
3. Oxygen pressure was too low with the result that the top edge has melted over because of
the slow cutting speed.
4. Oxygen pressure was too high and the nozzle size too small with the result that the entire
control of the cut has been lost.
5. Cutting speed was too slow with the result that the irregularities of the draglines are
emphasized.
6. Cutting speed was too high with the result that there is a pronounced break to the
dragline and the cut edge is irregular.

Course Title:
SMAW Trainer
7. Torch travel was unsteady with the result that the cut edge is wavy and irregular.
8. Cut was lost and not carefully restarted with the result that bad gouges were caused at
the restarting point.

Course Title:
SMAW Trainer
Elements of Good and Poor Cut
Multiple Choice:
Direction: Read and analyze the statement carefully, choose the best answer and write the
1. These are elements in producing good cuts except

a. Edge is square
b. Speed is too fast and too slow
c. Drag lines are essentially vertical
d. No adhering slag at the bottom edge of the cut
2. What will be the effect when preheat flames is not enough for the cutting process?
a. over melted top edge
b. bad gouging at the bottom
c. cut edge is wavy and irregular
d. excessive amount of adhering slag
3. Cutting speed was too high resulting to

a. bad gouging
b. cut edge is wavy and irregular
c. draglines are essentially vertical
d. break to the dragline and the cut edge is irregular
4. What causes good cuts?

b. required cutting tip for the job
c. Tip and torch angles incorrect
d. Preheat flame far from workpiece
e. Working pressure incorrectly set

Course Title:
SMAW Trainer
1. b
2. b
3. d
4. a

Course Title:
SMAW Trainer
Cutting Operation Procedures
Objectives:
1. Cut materials properly using oxy-acetylene cutting outfit.

2. Restarting a cut of the materials.
Oxyfuel gas cutting torch works when the metal being cut is rapidly oxidizes or burns. This
rapid oxidization or burning occurs when a high-pressure stream of pure oxygen is directed on the
metal after it has been preheated to a temperature above its kindling point.
Kindling point is the lowest temperature at which a material will burn. The kindling
temperature of iron is 1,6000F (8700C), which is dull red color.
Procedures in Cutting
1. Place the cutting tip so that the preheat flame is half on the metal and half off the edge of the
metal and the tip is perpendicular to the metal surface.
2. The tips of the inner cones should be as close as possible to the metal without touching it.
3. Preheat starting point until metal is cherry red, then slowly depress the oxygen cutting lever.
4. When cutting starts tilt the cutting tip slightly in the direction of the cut and move the tip at a
constant speed along the cut line.

Course Title:
SMAW Trainer
Basic Technique for Cutting Straight Lines
1. Hold the torch in your right hand with your thumb on the cutting lever and the torch centred in
front of your body.
2. Support the torch in your left hand with a relaxed grip that will permit the torch to be turned.
3. As you move the torch along the cutting line, roll your left hand slightly to the left from time to
time to make the adjustment required to keep the cutting flame straight along the line.
Note: The slight rolling technique with the left hand is the secret to good, straight cuts, so make some
dry runs until you get the feel of it.
Guide with
right hand
Support with left hand and use slight
rolling movement
Guidelines for Controlling Kerf and Drag
1. Good oxy-acetylene cutting should

produce a clean kerf with minimum drag,
and this requires proper tip selection,
travel speed, and proper fuel gas pressure.
2. The thickness of the metal being cut should dictate tip selection and fuel gas pressure, but cutting
torch angle is also important for a clean cut
For plate thickness 1/4” and less, the torch should be angled about 40 º- 50 º from the base
metal surface.

Course Title:
SMAW Trainer
For plate thickness from ¼” – ½”, the torch should be angled about 60 º - 70 ° from the base
metal surface.
For plate thickness over ½”, the torch should be held perpendicular to the plate.
Techniques for Restarting a Cut
1. Anytime cutting stops, release the oxygen cutting lever immediately, preheat the restarting point
at the edge only, and start again as if beginning a cut.
2. Blowholes are the biggest problem with restarting a cut, and blowholes can be avoided by:
2.1 Stopping torch travel before releasing the oxygen cutting lever.
Note:
This is especially effective on long cuts that you know will have or more restarting
points.
2.2 Moving the torch into the

scrap area beyond the cutting
line to form a corner or a curl
about 1/4 “ long so the cut
can be restarted in the scrap
area and moved cleanly back
to the original cutting line
Note: This technique permits you to reposition the torch at comfortable intervals on long cuts,
and when properly executed, the re-entry point along the cut line can hardly be detected.
3. Avoid cutting across slag when restarting because the slag will fly in all directions and create a
hazard

Course Title:
SMAW Trainer
Cutting Operation Procedures
YES NO
1. What do you call the lowest temperature a material will burn?
2. Tip of the cutting torch is properly positioned during cutting
operation.
3. Correct angle of the cutting torch is observed.
4. Applied proper techniques in restarting a cut.
5. Produced good cut.
6. Safety practices are observed during cutting operation.


Course Title:
SMAW Trainer
Use of Portable Angle Grinder
Objective:
At the end of the lesson the trainees are expected to,
1. Observe proper procedures in operating portable angle grinder.
Tools, Equipment and Materials:

A. Bench Vise
B. Portable Angle Grinder
C. Open Wrench
D. Abrasive Wheel
E. Grinding Wheel
F. Spanner
G. Metal Stock to be grinded
H. Safety Equipment (PPE)
Before any operation to be made using the portable angle grinder, you must have to check the size of
the grinding/cutting wheel attached to the grinder. Small diameter grinding/cutting wheel need to be
replaced to avoid damage or untoward incidents to the operator and nearby observer.
Replacing an Old Grinding Wheel
1. Unplug cord from the outlet.
2. Insert open wrench to the grinder spindle to counter

act the lock nut as the lock nut is turned
counter clockwise by the spanner.
3. Insert the new wheel and rotate the

lock nut clockwise to insure firm
and flat rotation of an
abrasive wheel.

Course Title:
SMAW Trainer
Procedures in Using Hand Grinder (Portable Angle Grinder)
1. Connect the plug to the

power outlet.
2. Position the hand grinder to the

workpiece to be ground and
hold it firmly to limit
vibration when
operating.
3. Start gripping the switch and move

the grinder slowly leftward and
rightward parallel to the
work piece until you
can obtained a
smooth surface.
Note:
Bevelling the material using portable angle grinder should be single stroke process to avoid
irregularities on surfaces.
Figure below shows the appearance of the material after grinding.
In operating the grinder, use a safety outfit as shown.

Course Title:
SMAW Trainer
Course Title:
SMAW Trainer
Use of Portable Angle Grinder
Performance
Criteria Yes No
1. Replaced grinding/cutting wheel.
2. Checked grinding/cutting wheel alignment.
3. Produced flat surface metal stock using portable angle grinder
4. Observe safety practices during operation.
Feedback to the candidate:
Overall Remarks

Trainer’s Signature: `Date:

Course Title:
SMAW Trainer
Operation Sheet no. 6.2-3
Prepare Edges and Surfaces of Plates and Pipes
Objective:
1. Produce smooth flat surfaces on metal stock.
Tools, Equipment and Materials

A. Bench Vise
B. Flat File (single cut)
C. Mild Steel
D. File Brush (Wire Brush)
E. Safety Equipment (PPE)
Filing is a method of removing small amounts of materials from the surface of a piece of metal or other
solid substances. In some respects, the operation is compared to smoothing a piece of wood with a chisel or
plane. Just as there are many types of chisel or planes to suit many different operations with wood, so there
are many types of files designed for specific types pf work and for various kinds of metals.
General Procedures
A. Preparation
1. As shown in the illustration below,
insert the file into the handle
tightly. Always check fitness
of the file handle before using
2. Clamp work securely allowing

portion to be filed protruding
from vise jaw.
B. Hold the file handle

1. Place the file handle on the palm,
thumb on the upper side while
the other fingers on the lower side.
C. Take position
1. Place the file tip horizontally at the
center of the work and up while
bending the right elbow at
the right angle.

Course Title:
SMAW Trainer
2. Face to the right a little
for the position of the feet.
3. Advance right/left leg by a step.
4. Place left hand palm to the tip of the file.
5. Set the right elbow close to the side of the chest and adjust the leg position so that the file
thumb and elbow are on horizontal line.
D. Forward backward motion.
1. Bend the left leg slightly and incline the upper body forward at the same time keeping the
eyes on the work.
2. Push the file horizontally applying required pressure to the handle and tip.

Course Title:
SMAW Trainer
3. Pull file horizontally without applying pressure until pushing position.
4. Repeat operation until desired finished is attained. “Filing is 30 – 40 strokes per minute”.
When the file surface is choked with hip, wipe out the chip by the file brush. Be sure to
brush along the blade teeth.
Note:
Materials subjected to filing must be free from contaminants. Square edge must also be
observed after the process.
Precautions:
1. Use the full length of the file surface.

2. When pushing forward, do not pull the waist but push out.
3. When chips cannot be removed by file brush, use nail or other pointed tools.
4. File is brittle, so do not use it as a hammer.

Course Title:
SMAW Trainer
Performance Criteria
Performance
Criteria
Yes No
1. Select correct type of tools for the job.
2. Proper positioning of the body during filing is observed.
3. Filing technique is applied.
4. Produce smooth flat surfaces of the metal stock.
5. Observe safety practices in cutting metal stocks.
Feedback to candidate:
Overall remarks


Course Title:
SMAW Trainer
Qualification : SMAW NC I
Learning Outcome #3 : Prepare Welding Consumables
CONTENTS:
1. Consumable material specifications

2. Equipments and tools for preparing plates and pipes
3. Safe working practices in preparing consumables
1. Consumables, materials, specified and quantity determined in accordance with job

requirements.
2. Correct materials selected in accordance with job requirements
Resources:

CBLM in Prepare weld
Welding tools Cutting equipments
materials
materials
Welding supplies and
materials
Evaluation Method:
 Written Test
 Demonstration
 Interview

Course Title:
SMAW Trainer
Learning Experience
LEARNING OUTCOME # 3: Prepare Welding Consumables
1. Read Operation Sheet No. 6.3-1 If you have some problem on the content of the information
Consumable materials sheet don’t hesitate to approach your facilitator.
specifications
the next information sheet. If not review the information
Equipment and tools for preparing sheet don’t hesitate to approach your facilitator.
plates and pipes
Safe working practices in preparing sheet don’t hesitate to approach your facilitator.
consumables

Course Title:
SMAW Trainer
Carbon Steel Materials
Objective:
At the end of the lesson, the trainees are expected to,
1. Identify the different types of carbon steel materials.
Carbon steel, also called plain-carbon steel is where the main interstitial alloying constituent is
carbon. The American Iron and Steel Institute (AISI) defines carbon steel as: “Steel is considered to be carbon
steel when no minimum content is specified or required for chromium, cobalt, molybdenum, nickel, niobium,
titanium, tungsten, vanadium, or zirconium, or any other element to be added to obtain a desired alloying
effect; when the specified minimum for copper does not exceed 0.40 percent; or when the maximum content
specified for any of the following elements does not exceed the percentages noted: manganese 1.65, silicon
0.60, copper 0.60.
The term “carbon steel” may also be used in reference to steel which is not stainless steel; in this use
carbon steel may include alloy papers.
As the carbon steel content rises, steel has the ability to become harder and stronger through heat
treating, but this also makes it less ductile. Regardless of the heat treatment, higher carbon content reduces
weldability. In carbon steels, the higher the carbon content lowers the melting point.
Mild Steel
The most common forms of steel because

its price is relatively low while it provides material
properties that are acceptable for many
applications. This contains 0.16 – 0.29%
carbonconten
Low Carbon Steel

Low carbon steel contains approximately
0.05 – 0.15% carbon.
Mild steel and low carbon steel are malleable

and ductile but it cannot be hardened by heat
treatment. Mild steel has relatively low tensile
strength, but it is cheap and malleable; surface
hardness can be increased through carburizing.
Medium Carbon Steel

Approximately 0.30 – 0.59% carbon
content. Balances ductility and strength and
has good wear resistance; used for large
parts, forging and automotive components.

Course Title:
SMAW Trainer
High Carbon Steel
Approximately 0.6 – 0.99% carbon content.
Very strong used for springs and high-strength wires.
Ultra-High Carbon Steel
Approximately 1.0 – 2.0% carbon content. Steels that can be tempered to great hardness. Used for
special purposes like (non-industrial-purpose) knives, axles or punches. Most steel with more than 1.2%
carbon content are made using powder metallurgy. Note that the steel with carbon content above 2.0 is
considered cast iron.

Course Title:
SMAW Trainer
Multiple Choice:
Direction: Read and analyse the statement carefully. Choose the best answer and write the letter only
in your answer sheet.
1. What will be the effect in welding when the carbon content of the material is high?
a. Ductile
b. Malleable
c. Weldable
d. Reduce weldability
2. Carbon steel with carbon content ranges from 0.16 – 0.29%.

a. Mild steel
b. Low carbon steel
c. High carbon steel
d. Medium carbon steel
3. Materials mostly used for ship building.

a. Mild steel
b. High carbon steel
c. Medium carbon steel
d. Ultra high carbon steel
4. Medium carbon steel are widely used in

a. Metal fabrication industry
b. Ship building industry
c. Automotive industry
d. Structural industry
5. The higher the carbon content, the material is

a. Ductile
b. Malleable
c. Increase weldability
d. Hard and tough

Course Title:
SMAW Trainer
1. d
2. a
3. a
4. c
5. c

Course Title:
SMAW Trainer
Identifying Metal using Sparks Test
Objective:
1. Identify carbon steel materials used for welding.
There is a very large range of steels available. And it is important to be able to identify a
particular type.
I. Bars of steel are branded by the manufacturer.

Two methods used are:
1. Stamping on the end.
2. Printing a color code on the end.
II. If you have to cut bars:
 Cut the unbranded end, if possible; or

 Make a note of the brand before cutting; and
 Remark the end immediately after cutting.
III. Handbooks and wall charts are available from steel suppliers:
1. To identify steels
2. To specify heat treatments for steels.
IV. Your workshop may have its own special method for identifying steels.
V. Make yourself familiar with this system.
VI. Whenever you have any doubt about the steel to be used, check with your supervisor. Positive
identification is important.

Course Title:
SMAW Trainer
VII. Try to learn all the possible ways of identifying metals by their distinctive properties, for example:
a.) Copper has a distinctive appearance.

b.) Aluminium has a very low density.
c.) Some stainless steels are non-magnetic.
VIII. The corner of a file will cut the unhardened part of a piece of steel but will slide over the hardened
part.
Grinding process is another method of determining the classification of the materials to be welded. The
shapes and sizes of the sparks coming from the grinding process illustrate the carbon content of the materials.
CAUTION:
Before you attempt to test yourself, you must be trained to use a grinding machine correctly. The wearing
of safety goggles is the first essential.
A. Low carbon steel -- produces long

white club-shaped sparks.
B. Medium carbon steel -- produces a mixture of

long white streaks and bursts of redder sparks.
C. High carbon tool steel-- produces a

shower of small bursting red sparks.
IX. Study the appearance of sparks from each of the known specimens in turn.
X. Next try to identify some unknown steel samples. Practice until you are sure of your ability to
recognize the appearance of each set of sparks.
XI. Remember that it is best to have as many separate indications as possible when identifying a metal.

Course Title:
SMAW Trainer
Course Title:
SMAW Trainer
Multiple Choice:
Direction: Read and analyse the statement carefully. Choose the best answer and write the letter only
in your answer sheet.
1. Characteristics of the material that has the ability to be weld easily?

a. Hardness
b. Ductility
c. Weldability
d. Malleability
2. What is the most distinct characteristic of the carbon steel compared to non-ferrous materials?
a. Hard
b. Heavy
c. Tough
d. Low density
3. What process would be considered to secure the classification of the material if it has the tendency
to be cut?
a. Remove the stamp on the end of the material
b. Cut the unbranded end of the material
c. Cut the material’s code
d. All of the above
4. This material produces long white club-shaped sparks during grinding.

a. Carbon steel
b. Low carbon steel
d. High carbon steel
5. During grinding, the material produces a shower of small bursting red sparks.
a. Carbon steel
b. Low carbon steel
d. High carbon steel

Course Title:
SMAW Trainer
1. c
2. b
3. c
4. b
5. d

Course Title:
SMAW Trainer
Mild Steel Electrodes
Objectives:
1. Identify the different kinds of mild steel electrodes.
Mild steel electrodes are available in wide variety and each has a particular used because of its
welding characteristics, and the mechanical and physical properties of the weld metal due to the
composition of the flux coating.
1. Rutile Electrode – contains coatings (mineral titanium dioxide). It gives very stable arc and
is easy to strike and re-strike. It produces a smooth bead with readily detachable slag
coverings and very little spattering but low penetration weld. Because of their good gap
bridging ability they are suited for welding of poor fit-up work.
Example: E6012, E6013
2. Cellulosic Electrode – contains 30 – 40% cellulose coatings and are characterized by a

highly penetrating spray type arc, fast-freezing metal and thin brittle slag. The coating
must contain 3% - 7% moisture because drying will affect the operating characteristics.
3. Basic Low Hydrogen Electrode – contains a high proportion of basic materials such as
limes and fluorides. These coating elements have very low hydrogen content which has
been proven to be the main cause of under bead cracking when welding high carbon and
high sulphur steel.
4. Iron Powder Electrode – contains about 50% mineral iron oxide coatings which can give a
metal recovery rate of 110% - 130% of the weight of the core wire melted. This electrode
exhibits high melting rate, deep penetration and minimum spatter loss. Percentage of iron
powder can also be found in some rutile and basic coated electrodes.
Example: E6024, E7024, E7027

Course Title:
SMAW Trainer
Self – check No. 6.3-3
Multiple Choice:
Direction: Read and analyse the statement carefully. Choose the best answer and write the
1. Contains coatings like mineral titanium dioxide and it gives very stable arc and is easy to strike
and re-strike.
a. E6010
b. E6013
c. E7018
d. E7027
2. Characterized by a highly penetrating spray type arc, fast-freezing metal and thin brittle slag.
a. E6011
b. E6013
c. E7018
d. E7027
3. What makes the differences of mild steel electrodes in terms of chemical and physical properties of
the weld metal?
a. Size of the electrode
b. Length of the electrode
c. Specification of the electrode
d. Flux coating of the electrode
4. What is the main cause of under bead cracking when welding high carbon and high sulphur steel?
a. Limes
b. Fluorides
c. Hydrogen
d. Flux coating
5. A mild steel electrode that givesa high metal recovery rate of the weight of the core wire melted.
a. Rutile electrode
b. Cellulose electrode
c. Iron powder electrode
d. Low hydrogen electrode

Course Title:
SMAW Trainer
1. b
2. a
3. d
4. c
5. c

Course Title:
SMAW Trainer
Classification of Covered Electrodes
Objectives:
1. Identify the classifications of mild steel electrodes.
For easy identification of electrodes, welding standard associations like American Welding
Society (AWS) and Standard Association of Australia (AS) came out with electrode classification codes.
The two codes are almost similar except that AWS Code A5.1 used the Imperials System of
Measurements while AS Code 1553 used the ISO System. The AWS Code A5.1 is widely used in the
Philippines and shown by manufacturers on electrode and packets.
First Digit – Electric Arc Welding Electrode
First Two Digits – Allowable minimum Tensile Strength of Weld in Thousand Per Square Inch (PSI)
E 60XX = 60 000 psi
E 70XX = 70 000 psi
E 100 XX = 100 000 psi
Third Digit – Welding Position

E XX1X = all position
E XX2X = horizontal and flat only
E XX4X = flat position only
Fourth Digit – Type of Current and Kind of Coatings

E XXX0 – DCRP (cellulosic, Na)
E XXX1 – DCRP or AC (cellulosic, K)
E XXX2 – DCSP or AC (rutile, K, Na)
E XXX3 – DCSP or AC (high rutile, K)
E XXX4 – DCRP, DCSP, or AC (rutile, iron powder, K)
E XXX5 – DCRP (basic low hydrogen, Na)
E XXX6 – DCRP or AC (basic low hydrogen, Na)

Course Title:
SMAW Trainer
E XXX8 – DCRP or AC (basic low hydrogen, iron powder, K)
E XX20 – DCRP or AC (iron oxide, Na)
E XX27 – DCRP or DCSP or AC for flat position
DCSP or AC for horizontal fillets only
(iron oxide, iron powder)
E XX30 – DCRP or DCSP or AC (high iron oxide, Na)
Note:
DCRP – Direct Current Reverse Polarity or
DCEP – Direct Current Electrode Positive
DCSP - Direct Current Straight Polarity or
DCEN – Direct Current Electrode Negative
AC - Alternating Current
DCRP – the electrode is connected to the positive terminal and the work to the negative
terminal
DCSP – the electrode is connected to the negative terminal and the work to the positive
terminal

Course Title:
SMAW Trainer
Multiple Choice:
1. What is the tensile strength of E7018 electrode?

a. 60 000 psi
b. 70 000 psi
c. 80 000 psi
d. 100 000 psi
2. The following electrodes are applied in all position welding except,

a. E6011
b. E6013
c. E7018
d. E7027
3. What is the recommended current setting for E6010 electrodes?

a. AC
b. DCRP
c. DCSP
d. Both DCRP, DCSP or AC
4. What does the last digit number of the electrode classification indicates?
a. Electric arc
b. Tensile strength
c. Welding position
d. Type of current and flux coating
5. What is the flux coating of E6013 electrode?

a. Rutile Potassium
b. Cellulosic Sodium
c. Iron Oxide Iron Powder
d. Low Hydrogen Iron Powder

Course Title:
SMAW Trainer
1. b
2. d
3. b
4. d
5. a

Course Title:
SMAW Trainer
Function of the Flux Coating
Objectives:
1. Explain the functions of the flux coating of a covered electrode.
The flux coating of the electrode has several functions during the welding process. These are
described below.
1. To form a gaseous atmosphere which protects the weld pool, the molten end of the
electrode and transferring droplets. Without such shielding, there would be chemical
reaction between the molten metal, and oxygen nitrogen from the air which would be
embrittle the deposit and cause porosity
2. To form a molten slag this floats to the surface of the weld pool to form a protective cover.
3. To add “de-oxidizers” to the weld pool that reduces the amount of harmful oxygen.
4. To reduce the resistance to current flow across the arc. Arc stabilizing elements assist arc
striking and improve arc stability.
5. To provide a means of adding alloy to the weld

metal and restoring the elements lost in transfer
from the core.
6. The slag cover of the freezing weld produces

a less rippled surface which merges more
smoothly with the base metal
7. Addition of iron powder increases deposition

rates and improves weld appearance and ease of
welding.
8. The flux coating influences the arc and metal

transfer characteristics which determine the
special application of the electrode.

Course Title:
SMAW Trainer
Multiple Choice:
1. To form a gaseous atmosphere which protects the weld pool, the molten end of the electrode and
transferring droplets.
a. De-oxidizers
b. Adding alloy
c. Arc stabilizer
d. Shielding gas
2. One of the functions of the flux coating is to reduce the harmful effects of oxygen in the welding
process.
a. De-oxidizers
b. Adding alloy
c. Arc stabilizer
d. Shielding gas
3. What is the purpose of adding iron powder to the flux coating of the electrode?
a. Reduce harmful oxygen
b. Increases deposition rates
c. Influences arc and metal transfer
d. Restore the elements lost in transfer from the core
4. What would be the effect when there is no protective gas during the welding process?
a. Porosity
b. Undercut
c. Slag inclusion
d. Incomplete fusion
5. Reduces the resistance to current flow across the arc during welding.
a. De-oxidizers
b. Adding alloy
c. Arc stabilizer
d. Shielding gas

Course Title:
SMAW Trainer
1. d
2. a
3. b
4. a
5. c

Course Title:
SMAW Trainer
Rule-of-Thumb Method
Objectives:
1. Apply rule-of-thumb method on identified size of electrode.
A rule-of-thumb method may be used to find a trial amperage when a manufacturer’s

electrode guide is not available. This method works well for electrode diameters between 3/32 “ (2.4
mm) and 1/4 “ (6.4 mm)
A 1/8 “ (3.2 mm) electrode diameter requires a 90 A – 120 A
Add 40 A to the 90 A for each 1/32” (0.8 mm) diameter above 1/8” 3.2 mm) diameter
electrode
Subtract 40 A from the 90 A for each 1/32” of diameter of electrode elow 1/8” diameter
of electrode.
Example:
Determine what amperage should be set on the welding machine when using
3/16” (4.8 mm) diameter electrodes.
Step 1 – 1/8” diameter electrode = 90 A
Step 2 – Determine the difference between 3/16” and 1/8”

3/16 “ – 1/8 “ = 1/16”
Step 3 – Convert 1/16” to 32nds of an inch

1/16’ = 2/32”
Step 4 – Multiply the numbers of 32nds by 40 A

2 x 40 = 80 A
Step 5 – Add the 90 A from step 1 to the answer in step 4.

90 A + 80 A = 170 A
The amperage obtained by using the manufacturer’s electrode guide and the rule-of-thumb
method may need to be modified. The position of the weld and the skill of the welder determine the
final amperage setting. Inspect the weld to determine whether the amperage needs to be raised or
lowered.

Course Title:
SMAW Trainer
Activity Sheet No. 6.3-1
Problem Solving:
Direction: Using the Rule-of-Thumb Method, compute for the required current settings of the
given sizes of electrode.
a. 5/32” Ø electrode
b. 2.4 mm Ø electrode

Course Title:
SMAW Trainer
a. 130 Amp
b. 50 Amp

Course Title:
SMAW Trainer
Competency Assessment
Multiple Choice:
1. Fuel gas and oxygen gas mixed together at the __________ of the torch.
a. gas hose
b. blow pipe
c. cutting tip
2. What is the recommended size of cutting tip to cut ½” thick plates?

a. 00
b. 1
c. 2
d. 3
3. What is the recommended flame for cutting ½” thick carbon steel plates?
a. Neutral flame
b. Oxidizing flame
c. Preheating flame
d. Carburizing flame
4. Dust or grit may be accumulated in the valve opening that causes the smoothly flow of gases
during operation.
a. purging
b. cracking
c. clearing
d. all of the above
5. What is the recommended flame for cutting ½” thick carbon steel plates?
a. Neutral flame
b. Oxidizing flame
c. Preheating flame
d. Carburizing flame
6. During this cutting process, the material is not cut into two pieces but instead a groove is cut to a
certain depth.
a. Gouging
b. Pipe beveling
c. Shape cutting
7. Adjustable to many steel forms including rod and pipe and can be used to cut horizontally or
vertically.
a. Pipe beveling
b. Shape cutting

Course Title:
SMAW Trainer
8. These are elements in producing good cuts except
a. Edge is square
b. Speed is too fast and too slow
c. Drag lines are essentially vertical
d. No adhering slag at the bottom edge of the cut
9. What will be the effect in welding when the carbon content of the material is high?
a. Ductile
b. Malleable
c. Weldable
d. Reduce weldability
10. Materials mostly used for ship building.

a. Mild steel
b. High carbon steel
d. Ultra high carbon steel
11. The higher the carbon content, the material is

a. Ductile
b. Malleable
c. Increase weldability
d. Hard and tough
12. Characterized by a highly penetrating spray type arc, fast-freezing metal and thin brittle slag.
a. E6011
b. E6013
c. E7018
d. E7027
13. What is the main cause of under bead cracking when welding high carbon and high sulphur
steel?
a. Limes
b. Fluorides
c. Hydrogen
d. Flux coating
14. To form a gaseous atmosphere which protects the weld pool, the molten end of the electrode
and transferring droplets.
a. De-oxidizers
b. Adding alloy
c. Arc stabilizer
d. Shielding gas
15. What would be the effect when there is no protective gas during the welding process?
a. Porosity
b. Undercut
c. Slag inclusion
d. Incomplete fusion

Course Title:
SMAW Trainer
Prepare Weld Materials
Answer Key
1. b
2. b
3. a
4. b
5. a
6. a
7. d
8. b
9. d
10. a
11. d
12. a
13. c
14. d
15. a

Course Title:
SMAW Trainer
Competency Assessment
Prepare Weld Materials
Performance Criteria
Trainee’s Name
Facilitator’s Name
Qualification
Given the necessary supplies, materials, tools and equipment, the PERFORMANCE
candidate must be able to prepare weld materials in accordance
with WPS.
Observation: YES NO
2. Cut and prepare edge of the materials (straight cut and/or
bevel cut)
3. Clean surfaces and edges using flat file.
4. Handle tools and equipment properly
5. Safety practices are observed.

Facilitator’s Signature Date:

Course Title:
SMAW Trainer

6 Prepare Weld Materials

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COMPETENCY BASED LEARNING MATERIAL

Technical Education and Skills Development Authority

Sector: Date Developed: Document No.:

Recognition of Prior Learning (RPL)

Sector: Date Developed: Document No.:

Sector: Date Developed: Document No.:

Sector: Date Developed: Document No.:

UNIT OF COMPETENCY Prepare Weld Materials

MODULE TITLE Preparing Weld Materials

NOMINAL DURATION: 5 hours

At the end of this module you MUST be able to:

1. Set-up cutting equipment

Sector: Date Developed: Document No.:

Module Title: Preparing Weld Materials

Learning Outcome Learning Content Progress Check Training Page

1. Set-up cutting 1. Parts and function of Self-check

4. Prepare welding 1. Consumable materials Self-check

Sector: Date Developed: Document No.:

Unit of Competency : Prepare Weld Materials

Module Title: Preparing Weld Materials

Sector: Date Developed: Document No.:

Sector: Date Developed: Document No.:

b. Kerf – Cut made by the cutting torch

d. Slag – The porous oxidized residue left after oxyacetylene cutting.

g. Backfire – Flame goes out with a loud snap or pop.

h. Flashback – Flame burns back inside of the tip, hose or regulator.

Sector: Date Developed: Document No.:

Qualification : SMAW NCI

Unit of Competency : Prepare Weld Materials

Module Title : Preparing Weld Materials

Learning Outcome #1 : Set-up Cutting Equipment

Students/Trainees must be provided with the following:

Tools Equipment Supplies & Materials

Sector: Date Developed: Document No.:

LEARNING OUTCOME # 1:Set-up Cutting Equipment

Learning Activities Special Instructions

If you feel that you are now knowledgeable on the content of

If you have satisfied the standard, you can now proceed to

Sector: Date Developed: Document No.:

Parts and Functions of Oxy-acetylene Cutting Outfit

At the end of the lesson, the trainees are expected to;

1. Identify the parts and functions of the oxy-acetylene outfit.

Characteristics of oxyacetylene cutting

Parts of Oxy-acetylene Cutting/Welding Outfit

1. Fuel Gas Cylinder. Portable container

2. Oxygen Gas Cylinder. Seamless,

3. Pressure Regulator and Gauges.

Sector: Date Developed: Document No.:

Parts of Pressure Regulator

Sector: Date Developed: Document No.:

Parts and Functions of Oxy-acetylene Cutting Outfit

1. This serves as storage for fuel gases and oxygen.

3. High pressure gauge of the pressure regulator indicates

4. Oxygen hose colored green with nuts threaded as

Sector: Date Developed: Document No.:

Sector: Date Developed: Document No.:

Parts and Functions of the Cutting Torch

At the end of the lesson, the trainees are expected to;

1. Identify the parts and functions of the cutting torch.

Parts of an Oxy-acetylene Cutting Torch