shielded metal arc welding (smaw) nc-1 - senior high school...this module contains information and...

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Shielded Metal Arc Welding (SMAW) NC-1 - Senior High School Alternative Delivery Mode Module 1: Preparing Weld Materials First Edition, 2020

Republic Act 8293, section 176 states that: No copyright shall subsist in any work of the Government of the Philippines. However, prior approval of the government agency or office wherein the work is created shall be necessary for exploitation of such work for profit. Such agency or office may, among other things, impose as a condition the payment of royalty.

Borrowed materials (i.e., songs, stories, poems, pictures, photos, brand names, trademarks, etc.) included in this book are owned by their respective copyright holders. Every effort has been exerted to locate and seek permission to use these materials from their respective copyright owners. The publisher and authors do not represent nor claim ownership over them. Published by the Department of Education – Region X – Northern Mindanao Regional Director: Dr. Arturo B. Bayocot, CESO V

Printed in the Philippines by Department of Education - Alternative Delivery Mode (DepEd-ADM) Office Address: Masterson Avenue, Upper Balulang, Zone 1, Cagayan de Oro

City, Cagayan de Oro, Lalawigan ng Misamis Oriental Telefax: ________________________________________________ E-mail Address: ________________________________________________

Development Team of the Module Authors: Aaron A. Adesas Marco Antonio E. Sosobrado Roy M. Legaspi Nolan V. Alvear Editors: Reviewers: Dexter A. Delfin

Lovenres J. Enanoria Ronald M. Ortega Illustrator and Layout Artist: Nolan V. Alvear Management Team: Purificacion J. Yap

Sherlita L. Daguisonan

Development Team of the Module:

Authors: Aaron A. Adesas Marco Antonio E. Sosobrado Roy M. Legaspi Nolan V. AlvearReviewers: Dexter A. Delfin Lovenres J. Enanoria Ronald M. OrtegaIllustrator: Nolan V. Alvear

Management Team:

Chairperson: Dr. Arturo B. Bayocot, CESO III Regional DirectorCo-Chairpersons: Dr. Victor G. De Gracia Jr., CESO V Asst. Regional Director Mala Epra B. Magnaong CES, CLMDMembers: Dr. Bienvenido U. Tagolimot, Jr. Regional ADM Coordinator Elson C. Jamero EPS-Designate-TLE

Printed in the Philippines by: Department of Education – Regional Office 10 Office Address: Zone 1, Upper Balulang Cagayan de Oro City 9000Telefax: (088) 880-7071, (088) 880-7072E-mail Address: [email protected]

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Shielded Metal Arc Welding (SMAW) NC-1 - Senior High School Alternative Delivery Mode Module 1: Preparing Weld Materials First Edition, 2020

Republic Act 8293, section 176 states that: No copyright shall subsist in any work of the Government of the Philippines. However, prior approval of the government agency or office wherein the work is created shall be necessary for exploitation of such work for profit. Such agency or office may, among other things, impose as a condition the payment of royalty.

Borrowed materials (i.e., songs, stories, poems, pictures, photos, brand names, trademarks, etc.) included in this book are owned by their respective copyright holders. Every effort has been exerted to locate and seek permission to use these materials from their respective copyright owners. The publisher and authors do not represent nor claim ownership over them. Published by the Department of Education – Region X – Northern Mindanao Regional Director: Dr. Arturo B. Bayocot, CESO V

Printed in the Philippines by Department of Education - Alternative Delivery Mode (DepEd-ADM) Office Address: Masterson Avenue, Upper Balulang, Zone 1, Cagayan de Oro

City, Cagayan de Oro, Lalawigan ng Misamis Oriental Telefax: ________________________________________________ E-mail Address: ________________________________________________

Development Team of the Module Authors: Aaron A. Adesas Marco Antonio E. Sosobrado Roy M. Legaspi Nolan V. Alvear Editors: Reviewers: Dexter A. Delfin

Lovenres J. Enanoria Ronald M. Ortega Illustrator and Layout Artist: Nolan V. Alvear Management Team: Purificacion J. Yap

Sherlita L. Daguisonan

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Department of Education Republic of the Philippines

Senior High School

Shielded Metal Arc Welding (SMAW) NC-1 Unit of Competency : Prepare Weld Materials

Module Title : Preparing Weld Materials

This instructional material was collaboratively developed and reviewed by educators from public and private schools, colleges, and or/universities. We encourage teachers and other education stakeholders to email their feedback, comments, and recommendations to the Department of Education at action@ deped.gov.ph.

We value your feedback and recommendations.

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Table of Contents What This Module is About.……………………………….………………………………….….1 Recognition of Prior Learning………………………………………………………….…………1 What I Need to Know…………………………………………….……………………………….2 How to Learn from this Module……………………………………………………………….….2 Technical Terms ………………………………………………………….……………......….….3 Icons of this Module……………………………………………………………………………….4 What I Know………………………………………………………………………………………..5 Learning Outcome #1 Set-up Cutting Equipment……………………….……………6

Learning Experiences/Activities ………………………………………….….………….6 Information Sheet #1.1.……………………………………………………….….………7 Operation Sheet # 1.2………………………………………………………………..….11 Self-Check #1.2 …………………………………………………………………...…….18

Learning Outcome #2 Cut and Prepare Edge of Materials.….……………………19

Learning Experiences/Activities …………………………….…………………………19 Information Sheet # 2.1 ………………………………………….…………….……….20 Self-Check #2.1 …………………………………………………….…………………...27 Operation Sheet 2.1 …………………………………………………………………….28

Learning Outcome #3 Prepare Welding Consumables ……….....……….……….29

Learning Experiences/Activities…………………………………………….………….29 Information Sheet # 3.1 ………………………………………………………...…...….30 Self-Check #3.1 ………………………………………………………………………….36

Learning Outcome #4 Clean Surfaces and Edges ………………………………….37

Learning Experiences/Activities ……………………………………………………….37 Information Sheet # 4.1 ……………………………………………………………..….38

Self-Check #4.1 ………………………………………………………….….….…….…40 Task Sheet #4,1 …………………………………………………………………………41 Learning Outcome #5 Prepare Protective Welding Equipment ………….….….42

Learning Experiences /Activities ………………………………………………………42 Information Sheet # 5.1 …………………………………………………........…….….43

Self-Check #5.1 ……………………………………………………………….………...45 Assessment: (Summative-Test) …………………………………………………….46 Answer Key ………………………………………………………………………………………48 References ……………………………………………………………………………………….49

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Table of Contents What This Module is About.……………………………….………………………………….….1 Recognition of Prior Learning………………………………………………………….…………1 What I Need to Know…………………………………………….……………………………….2 How to Learn from this Module……………………………………………………………….….2 Technical Terms ………………………………………………………….……………......….….3 Icons of this Module……………………………………………………………………………….4 What I Know………………………………………………………………………………………..5 Learning Outcome #1 Set-up Cutting Equipment……………………….……………6

Learning Experiences/Activities ………………………………………….….………….6 Information Sheet #1.1.……………………………………………………….….………7 Operation Sheet # 1.2………………………………………………………………..….11 Self-Check #1.2 …………………………………………………………………...…….18

Learning Outcome #2 Cut and Prepare Edge of Materials.….……………………19

Learning Experiences/Activities …………………………….…………………………19 Information Sheet # 2.1 ………………………………………….…………….……….20 Self-Check #2.1 …………………………………………………….…………………...27 Operation Sheet 2.1 …………………………………………………………………….28

Learning Outcome #3 Prepare Welding Consumables ……….....……….……….29

Learning Experiences/Activities…………………………………………….………….29 Information Sheet # 3.1 ………………………………………………………...…...….30 Self-Check #3.1 ………………………………………………………………………….36

Learning Outcome #4 Clean Surfaces and Edges ………………………………….37

Learning Experiences/Activities ……………………………………………………….37 Information Sheet # 4.1 ……………………………………………………………..….38

Self-Check #4.1 ………………………………………………………….….….…….…40 Task Sheet #4,1 …………………………………………………………………………41 Learning Outcome #5 Prepare Protective Welding Equipment ………….….….42

Learning Experiences /Activities ………………………………………………………42 Information Sheet # 5.1 …………………………………………………........…….….43

Self-Check #5.1 ……………………………………………………………….………...45 Assessment: (Summative-Test) …………………………………………………….46 Answer Key ………………………………………………………………………………………48 References ……………………………………………………………………………………….49

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What This Module is About

Welcome to the Module “PREPARING WELD MATERIALS”. This module contains training materials and activities for you to complete.

The unit of competency “Prepare Weld Materials” contains the knowledge, skills and

attitudes required for Shielded Metal Arc Welding (SMAW) required to obtain the National Certificate (NC) level I.

You are required to go through a series of learning activities in order to complete each

of the learning outcomes of the module. In each learning outcome there are Information Sheets, Job Sheets, Operation Sheets and Activity Sheets. Do these activities on your own and answer the Self-Check at the end of each learning activity?

If you have questions, do not hesitate to ask your teacher for assistance.

Recognition of Prior Learning (RPL)

You may already have some basic knowledge and skills covered in this module. If you can demonstrate competence to your teacher in a particular skill, talk to your teacher so you do not have to undergo the same training again.

If you have a qualification or Certificate of Competency from previous trainings show it to him/her. If the skills you acquired are consistent with and relevant to this module, they become part of the evidence. You can present these for RPL. If you are not sure about your competence skills, discuss this with your teacher.

After completing this module, ask your teacher to assess your competence. Result of your assessment will be recorded in your competency profile. All the learning activities are designed for you to complete at your own pace.

Inside this module, you will find the activities for you to complete and relevant information sheets for each learning outcome. Each learning outcome may have more than one learning activity.

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What I Need to Know

This module contains information and suggested learning activities on Preparing Weld Materials. It includes instruction and procedure on how to Prepare Weld Materials.

Completion of this module will help you better understand the succeeding module on Setting up Welding Equipment.

This module consists of five (5) learning outcomes. Each learning outcome contains learning activities supported by instruction sheets. Before you perform the instruction, read the information sheets and answer the self-check and activities provided. To ascertain your competence, your teacher will assess what you have acquired when the knowledge necessary to perform the skill portion of the what particular learning outcome.

Upon completing this module, report to your competent teacher for assessment to check your achievement of knowledge and skills requirements of this module. If you pass the assessment, you will be given a certificate of completion.

Upon completion of the module you should be able to:

• LO1 Set up cutting equipment TLE_IAAW9-12WMIa-b-1 • LO2 Cut and prepare edge of materials TLE_IAAW9-12WMIc-d-2 • LO3 Prepare welding consumables TLE_IAAW9-12WMIe-3 • LO4 Clean surfaces and edges TLE_IAAW9-12WMIf-4 • LO5 Prepare protective welding equipment TLE_IAAW9-12WMIg-5

How to Learn from this Module To achieve the objectives cited above, you are to do the following:

• Take your time reading the lessons carefully.

• Follow the directions and/or instructions in the activities and exercises diligently.

• Answer all the given tests and exercises.

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What I Need to Know

This module contains information and suggested learning activities on Preparing Weld Materials. It includes instruction and procedure on how to Prepare Weld Materials.

Completion of this module will help you better understand the succeeding module on Setting up Welding Equipment.

This module consists of five (5) learning outcomes. Each learning outcome contains learning activities supported by instruction sheets. Before you perform the instruction, read the information sheets and answer the self-check and activities provided. To ascertain your competence, your teacher will assess what you have acquired when the knowledge necessary to perform the skill portion of the what particular learning outcome.

Upon completing this module, report to your competent teacher for assessment to check your achievement of knowledge and skills requirements of this module. If you pass the assessment, you will be given a certificate of completion.

Upon completion of the module you should be able to:

• LO1 Set up cutting equipment TLE_IAAW9-12WMIa-b-1 • LO2 Cut and prepare edge of materials TLE_IAAW9-12WMIc-d-2 • LO3 Prepare welding consumables TLE_IAAW9-12WMIe-3 • LO4 Clean surfaces and edges TLE_IAAW9-12WMIf-4 • LO5 Prepare protective welding equipment TLE_IAAW9-12WMIg-5

How to Learn from this Module To achieve the objectives cited above, you are to do the following:

• Take your time reading the lessons carefully.

• Follow the directions and/or instructions in the activities and exercises diligently.

• Answer all the given tests and exercises.

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What is It

TECHNICAL TERMS 1. Oxy-acetylene is an equipment for cutting and welding outfit requires

compressed oxygen and acetylene gases.

2. Regulator a valve with controls flow of gases for processes such as welding by oxy-acetylene.

3. Gauges a device use to indicate the magnitude of pressure in the cylinder.

4. Working pressure gauge is the gauge attached to the regulator which determines the gas working pressure during cutting.

5. Welding torch is a device used in oxy-fuel gas welding, cutting, brazing, and soldering directing the heating flame produced by the controlled combustion of fuel gas.

6. Cutting outfit is a unit of cutting equipment used for cutting metals.

7. Plasma cutting is a process using plasma to transfer an electric arc to metal. The metal is heated to its melting point by the heat of the arc and blown away by air.

8. Coupling distance is the gap between the end of the pre-heat cones and the surface of the material being cut.

9. Gas flow is the amount of gas released from the regulator which passes through the hose towards the direction of the torch tip.

10. Gas storage an area free from fire hazard. A storage for tanks filled with proper air ventilation.

11. Gas volume is the amount of pressure gas.

12. Drying oven is an oven where electrodes are baked with a temperature from 200 0C – 300 0C.

13. LP Liquified Petroleum

14. MAPP(R) Methylacetylene Propadiene

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Icons of this Module

What I Need to Know

This part contains learning objectives that are set for you to learn as you go along the module.

What I know This is an assessment as to your level of knowledge to the subject matter at hand, meant specifically to gauge prior related knowledge

What’s In This part connects previous lesson with that of the current one.

What’s New An introduction of the new lesson through various activities, before it will be presented to you

What is It These are discussions of the activities as a way to deepen your discovery and under- standing of the concept.

What’s More These are follow-up activities that are in- tended for you to practice further in order to master the competencies.

What I Have Learned

Activities designed to process what you have learned from the lesson

What I can do These are tasks that are designed to show- case your skills and knowledge gained, and applied into real-life concerns and situations.

Additional Activities

An activity in any form that can increase the strength of the response and tends to induce repetitions of actions/learning

Answer Key

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Icons of this Module

What I Need to Know

This part contains learning objectives that are set for you to learn as you go along the module.

What I know This is an assessment as to your level of knowledge to the subject matter at hand, meant specifically to gauge prior related knowledge

What’s In This part connects previous lesson with that of the current one.

What’s New An introduction of the new lesson through various activities, before it will be presented to you

What is It These are discussions of the activities as a way to deepen your discovery and under- standing of the concept.

What’s More These are follow-up activities that are in- tended for you to practice further in order to master the competencies.

What I Have Learned

Activities designed to process what you have learned from the lesson

What I can do These are tasks that are designed to show- case your skills and knowledge gained, and applied into real-life concerns and situations.

Additional Activities

An activity in any form that can increase the strength of the response and tends to induce repetitions of actions/learning

Answer Key

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What I Know

Direction: Write the letter of the correct answer in every item. Provide a separate answer sheet.

1. Injection torches can use fuel gases with pressures as low as: a. 7 psi (0.49 kg/cm2) b. 2 psi (0.14 kg/cm2) c. 6 oz./in2 (26.3 g/cm2) d. 9 oz./in2 (39.4 g/cm2)

2. Oxygen and acetylene hoses should be color coded, which from the given answers is correct.

a. Oxygen green, Acetylene black or red b. Oxygen green or black, Acetylene red c. Oxygen green, Acetylene red d. Oxygen green or black, Acetylene red or black.

3. Considered as a line pressure gauge. a. Regulator b. Low pressure gauge c. High pressure gauge d. Valve gauge

4. A typical characteristic of a neutral flame. a. Acetylene and with excess Oxygen b. Balance of Acetylene and Oxygen c. Oxygen and with excess Acetylene d. Acetylene burning in the atmosphere

5. OFC is an acronym for: a. Oxy-fuel cutting b. Oxy-fused cutting c. Oxygen fueled cutting d. None of the above

6. The term “cracking” means: a. Blowing-out of dirt lodged in the valve. b. Release of gas from the torch valve. c. Release of gas from the pressure gauge. d. Release of gas from the torch tip.

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What I Need to Know Assessment Criteria:

1. Cutting equipment is set in conformity with acceptable standard. 2. Cutting equipment fittings, connection and the power source (flame) are checked

in accordance with the standard procedure.

Learning Experiences/Activities:

Learning Activities Special Instructions:

1. Read the attached Information Sheet # 1.1 and Operation sheet # 1.2

Answer the Self-check without referring to the operation sheet.

2. Answer Self-checks # 1.1 and # 1.2 Answer the Self-check in the least possible time allotted.

3. Compare your answer with answer keys Assignment sheet will be issued as an advance requirement prior to learning the next operation sheet.

4. If you failed to meet the 80% of equivalent passing standard, go over once again operation sheet and information sheet.

LO - 1 Set-up Cutting Equipment

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1. Cutting equipment is set in conformity with acceptable standard. 2. Cutting equipment fittings, connection and the power source (flame) are checked

in accordance with the standard procedure.

Learning Experiences/Activities:

Learning Activities Special Instructions:

1. Read the attached Information Sheet # 1.1 and Operation sheet # 1.2

Answer the Self-check without referring to the operation sheet.

2. Answer Self-checks # 1.1 and # 1.2 Answer the Self-check in the least possible time allotted.

3. Compare your answer with answer keys Assignment sheet will be issued as an advance requirement prior to learning the next operation sheet.

4. If you failed to meet the 80% of equivalent passing standard, go over once again operation sheet and information sheet.

LO - 1 Set-up Cutting Equipment

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What’s New

LO1: Set-up Cutting Equipment

Introduction:

Preparation of materials prior to welding is just one task to perform in the shop. The appropriate cutting equipment must be installed and properly used in order to meet the cutting requirement.

The activity is focused on the set-up of cutting equipment and includes the accurate mixture of gases applied to all cutting operations.

What Is It

Oxy-Acetylene Cutting Equipment

A typical oxy-acetylene cutting and welding outfit requires compressed oxygen and acetylene gases that are stored in the cylinders separately. Oxygen gas is placed in the tall tank and the acetylene gas is stored in the small tank.

Information Sheet 1.1

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Parts of the basic oxy-acetylene outfit:

1. Oxygen Cylinder - A tall tank cylinder where oxygen gas is stored. 2. Acetylene Cylinder – A tank of lesser height where acetylene gas is stored. 3. Regulator (Oxygen) – Separate regulator for oxygen pressure gauge. 4. Regulator (Acetylene) – A separate regulator with acetylene gas pressure gauge

that indicates the direction of the flow towards the torch body. 5. Acetylene Hose (Red) – A type of hose wherein acetylene gas flows towards the

direction of the torch body. 6. Oxygen Hose (Green) – A type of hose wherein oxygen gas flows towards the

direction of the torch body. 7. Safety Chain - A metal chain wrapped around the body of the cylinders and tied

securely in the metal frame stand.

Pressure Regulator

All regulators do the same type of job. They all work in the same principle whether they are of low or high pressure; single or multiple stages; cylinder, manifold, line, type with the gas they regulate. The regulator which reduces high pressure to lower working pressure must be held constant over a range of flow rates and volumes.

Working Pressure gauge - Measures pressure gas that flows or is released from the torch body to the nozzle or tip. Cylinder Pressure gauge - A registered gas pressure found in the cylinder. Safety release valve - Is made up of a small ball held tightly against a seat by a spring. Gauges - Show the working pressure and the other indicates the magnitude of pressure in the cylinder. Regulators - Work by holding the forces on both sides of a diaphragm in balance.

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Parts of the basic oxy-acetylene outfit:

1. Oxygen Cylinder - A tall tank cylinder where oxygen gas is stored. 2. Acetylene Cylinder – A tank of lesser height where acetylene gas is stored. 3. Regulator (Oxygen) – Separate regulator for oxygen pressure gauge. 4. Regulator (Acetylene) – A separate regulator with acetylene gas pressure gauge

that indicates the direction of the flow towards the torch body. 5. Acetylene Hose (Red) – A type of hose wherein acetylene gas flows towards the

direction of the torch body. 6. Oxygen Hose (Green) – A type of hose wherein oxygen gas flows towards the

direction of the torch body. 7. Safety Chain - A metal chain wrapped around the body of the cylinders and tied

securely in the metal frame stand.

Pressure Regulator

All regulators do the same type of job. They all work in the same principle whether they are of low or high pressure; single or multiple stages; cylinder, manifold, line, type with the gas they regulate. The regulator which reduces high pressure to lower working pressure must be held constant over a range of flow rates and volumes.

Working Pressure gauge - Measures pressure gas that flows or is released from the torch body to the nozzle or tip. Cylinder Pressure gauge - A registered gas pressure found in the cylinder. Safety release valve - Is made up of a small ball held tightly against a seat by a spring. Gauges - Show the working pressure and the other indicates the magnitude of pressure in the cylinder. Regulators - Work by holding the forces on both sides of a diaphragm in balance.

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There are varieties of inlet or cylinder fittings available to ensure that the regulator cannot be connected to the wrong gas or pressure (see figure A and figure B). A few adaptors are available that will allow some regulators to be attached to a different type of fitting.

A. Acetylene Cylinder Valve B. Oxygen Cylinder Valve

Two most common types:

1. Adapt a left-hand male acetylene cylinder fitting to a right-handed female regulator fitting or vice-versa.

2. Adapt a female acetylene cylinder fitting to a male regulator fitting.

Figure 1. Cutting attachment for welding torch. Courtesy of www.weldguro.com

Cutting Torch

Oxy-acetylene cutting torch is the same as oxy-fuel cutting torch. The assembly of torch vary in sizes for different types of work. There are small torches for jewelry work, large torches in heavy plates and special torches for heating, brazing and soldering. Some uses fuel-air mixture. There are no industrial standards for tip size, tip threads, or seats. Each style, size, and type of torch can be used only with tips made by the same manufacturer to fit-in the specific tank.

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The diagram showing how two gases, the fuel gas and oxygen mixed-up in the chamber with equal pressure. The two gases are completely mixed before they leave the tip and create the flame.

(Methods of mixing oxygen and fuel gas to produce flames)

1. Uses equal balance pressures; the gases are mixed in the mixing chamber. 2. Uses a higher oxygen pressure; the gases are mixed in the injection chamber.

A diagram showing a metal coil in the oxygen tube spinning the gas ensuring a complete mixing of gases.

A diagram showing an injector mixing system. The injector torch works both with equal gas pressure or low fuel gas pressures. The injector allows oxygen at the higher pressure to draw the fuel gas into the chamber, even when the fuel gas pressure is as low as 26.3 g/cm2. The injector works by passing the oxygen through a venturi which create a vacuum to pull the fuel gas in and then mixes the gases together. An injector-type torch should be used in a low-pressure acetylene generator or a low-pressure residual.

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The diagram showing how two gases, the fuel gas and oxygen mixed-up in the chamber with equal pressure. The two gases are completely mixed before they leave the tip and create the flame.

(Methods of mixing oxygen and fuel gas to produce flames)

1. Uses equal balance pressures; the gases are mixed in the mixing chamber. 2. Uses a higher oxygen pressure; the gases are mixed in the injection chamber.

A diagram showing a metal coil in the oxygen tube spinning the gas ensuring a complete mixing of gases.

A diagram showing an injector mixing system. The injector torch works both with equal gas pressure or low fuel gas pressures. The injector allows oxygen at the higher pressure to draw the fuel gas into the chamber, even when the fuel gas pressure is as low as 26.3 g/cm2. The injector works by passing the oxygen through a venturi which create a vacuum to pull the fuel gas in and then mixes the gases together. An injector-type torch should be used in a low-pressure acetylene generator or a low-pressure residual.

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What I Can Do

Procedures in Setting-up a Cutting Equipment

1. Secure oxygen and acetylene cylinders to the cart or wall before the removal of the safety caps.

Source: http://www.youtube.com/watch?v=BqOguEo-ors&feature=related

2. After removing the safety caps, stand to one side and crack (open, then quickly close) the cylinder valves to ensure no dust and/or any other may be a source for ignition of fire.


Operation Sheet 1.2

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3. Visually check all parts for any damage. 4. Attach the regulators to the cylinder valves, and tighten securely with a wrench.

Installing regulator using a special kind of wrench


5. Attach the reverse flow valves in the gas outlet, and then attach the hose.

6. If the torch is a combination-type torch, attach the cutting head.

Attaching the torch flame pipe to the hose

The reverse flow valve is already attached to the regulator before attaching the hose connector.

Tightening of the hose connection.

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3. Visually check all parts for any damage. 4. Attach the regulators to the cylinder valves, and tighten securely with a wrench.

Installing regulator using a special kind of wrench


5. Attach the reverse flow valves in the gas outlet, and then attach the hose.

6. If the torch is a combination-type torch, attach the cutting head.

Attaching the torch flame pipe to the hose

The reverse flow valve is already attached to the regulator before attaching the hose connector.

Tightening of the hose connection.

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7. Install the cutting tip in the torch.

Typical cutting torch assembly with attached torch tip

8. Before the cylinder valve is opened, back-out the pressure regulating screw so that the valve opens the gauge back to zero for welding pressure.


Turning the adjustable handle to back-out pressure and turn zero pound on meter gauge reading

9. Stand on the side of the regulator as the cylinder valve is opened slowly.

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Opening of cylinder valve to merge in the hose

Note: Oxygen valve is opened all the way until it becomes tight and acetylene valve is opened not more than half turn.

10. Open the acetylene torch valve (needle valve) and then turn the regulating screw slowly until 2 psi to 4 psi (1 ksi-2ksi) for working pressure gauge. Then close the needle valve (acetylene)

Turning the adjustable handle of the valve to regulate the amount of working pressure needed.

11. Open the oxygen torch valve (needle valve) and turn the regulating screw slowly until 4 to 6 psi for the working pressure gauge, then close the needle valve (oxygen)

If you are using a combination welding and cutting torch, the oxygen valve nearest the hose connection must be opened before the flame adjusting valve of cutting lever will work.

The oxygen valve near the hose connection must be opened, before the cutting lever will work.

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Opening of cylinder valve to merge in the hose

Note: Oxygen valve is opened all the way until it becomes tight and acetylene valve is opened not more than half turn.

10. Open the acetylene torch valve (needle valve) and then turn the regulating screw slowly until 2 psi to 4 psi (1 ksi-2ksi) for working pressure gauge. Then close the needle valve (acetylene)

Turning the adjustable handle of the valve to regulate the amount of working pressure needed.

11. Open the oxygen torch valve (needle valve) and turn the regulating screw slowly until 4 to 6 psi for the working pressure gauge, then close the needle valve (oxygen)

If you are using a combination welding and cutting torch, the oxygen valve nearest the hose connection must be opened before the flame adjusting valve of cutting lever will work.

The oxygen valve near the hose connection must be opened, before the cutting lever will work.

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12. Cutting set-up is ready for the next task.

Calibration of the Cutting Equipment

During the set-up and operation of the cutting equipment, there are several observable things that might occur which need immediate attention. One of these is the failure of the cutting unit to function well and requires adjustment and correction. The student will be guided for some of the recommended practices.

Oxygen and acetylene pressures for different cutting and welding jobs

Tip # Thickness of metal (mm) Oxy-acetylene

Pressure Psi(kpa)

Acetylene Flow (cfh)

Oxygen flow (cfh)

00 0.3 1 0.1 0.1 0 0.7 1 0.4 0.4 1 1.5 1 1 1.1 2 2.3 2 2 2.2 3 3.1 3 8 8.8 4 4.7 4 17 18 5 6.3 5 25 27 6 7.9 6 34 37 7 9.5 7 43 47 8 12.7 8 52 57 9 15.8 9 59 64

10 19.0 10 67 73 Where:

mm - millimeter cfh – cubic feet per hour psi – pounds per square inch

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The table shows the tip size, thickness of metal, work pressure and the speed. For cutting, use larger size of tip with corresponding data as shown in the table above. This information will support the succeeding activities in relation to cutting of materials.

Checking Gas Leaks

Check gas leaks

There is now a pressured gas throughout the system. A mixture of soapy water is applied to all regulators, the hose connection and other fittings to check its appropriateness.

After checking, gas leaks may occur through the reaction of a soap solution, the connection has to be tightened properly. If no more leaks are found, reopen the torch valve.

Caution: Leaking cylinder valve stem should not be repaired when gas pressure is present. Turn

off the valve, disconnect cylinder and mark or label the defective unit.

Cracking oxygen and fuel cylinder valves

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The table shows the tip size, thickness of metal, work pressure and the speed. For cutting, use larger size of tip with corresponding data as shown in the table above. This information will support the succeeding activities in relation to cutting of materials.

Checking Gas Leaks

Check gas leaks

There is now a pressured gas throughout the system. A mixture of soapy water is applied to all regulators, the hose connection and other fittings to check its appropriateness.

After checking, gas leaks may occur through the reaction of a soap solution, the connection has to be tightened properly. If no more leaks are found, reopen the torch valve.

Caution: Leaking cylinder valve stem should not be repaired when gas pressure is present. Turn

off the valve, disconnect cylinder and mark or label the defective unit.

Cracking oxygen and fuel cylinder valves

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“Cracking” is one way of blowing out any dirt lodged in the valve. The quick release and the sudden closing of the valve should be done. This is applicable for both oxygen and fuel gas.

Caution: Face the valve of cylinders away from any source of ignition or any object or a person that

might be damaged or harmed by the flame when it is lit.

Checking or cutting tip for leaks

Check the assembled torch tip for a good seal, place your thumb over the end of the tip, turn on oxygen valve, and spray the tip with a leak detecting selection.

18

What I Have Learned SELF-CHECK # 1.2 (OPERATION SHEET)

Directions:

Use the check-list below as basis for judging whether you meet the required competency. Write YES or NO for your answer in a separate answer sheet.

Performance Indicators YES NO

1. Can secure Oxygen and Acetylene cylinders to the cart or wall correctly.

2. Can remove safety caps and crack cylinder valve properly.

3. Can check all parts for any damage.

4. Can attach regulators to cylinders securely.

5. Can attach flow valves and hoses to the gas outlet.

6. Can install the cutting tip. 7. Can back-out the pressure regulating screw before opening the cylinder

valves.

8. Can adjust the regulating screw to satisfy the working pressure needed.

9. Can set-up cutting outfit correctly ready for use.

What’s More

For Further Study

Have learners assess their performance. For criteria needing assistance, provide the appropriate intervention/s.

18

What I Have Learned SELF-CHECK # 1.2 (OPERATION SHEET)

Directions:

Use the check-list below as basis for judging whether you meet the required competency. Write YES or NO for your answer in a separate answer sheet.

Performance Indicators YES NO

1. Can secure Oxygen and Acetylene cylinders to the cart or wall correctly.

2. Can remove safety caps and crack cylinder valve properly.

3. Can check all parts for any damage.

4. Can attach regulators to cylinders securely.

5. Can attach flow valves and hoses to the gas outlet.

6. Can install the cutting tip. 7. Can back-out the pressure regulating screw before opening the cylinder

valves.

8. Can adjust the regulating screw to satisfy the working pressure needed.

9. Can set-up cutting outfit correctly ready for use.

What’s More

For Further Study

Have learners assess their performance. For criteria needing assistance, provide the appropriate intervention/s.

19


1. Materials are cut to the specified dimensions and specifications. 2. Tasks are performed in accordance with the work standard.

LEARNING EXPERIENCES/ACTIVITIES

Learning Outcome 2: Cut and prepare edge materials

Learning Activities Special Instructions

1. Read the attached operation sheet # 2.1 and know to cut and prepare edge materials.

2. Answer the self-check # 2.1 to test your knowledge on cut and prepare edge materials.

3. Compare your answer on answer key

4. If you missed some items, go over this enabling objective again.

5. 5) When you are ready, you can proceed to the next enabling objective.

Answer the self-check without looking at the information sheet

LO - 2 Cut and Prepare Edge Materials

20

What’s New

LO2: Cut and prepare edge materials.

Introduction:

Metals are formed into structures by assembling or connecting each member parts through the process of welding. Therefore, the materials of varied sizes and thickness are cut and shaped with specific measurement and dimension. In this activity, the student shall develop skills in cutting materials with oxy-acetylene and discover other cutting outfit.

What is it

Flame Cutting Procedure

Pre-heat flame is properly adjusted and as you have taken all the safety measures, you are ready to do the actual cutting. You may see how fast cutting goes, but drills and practices will build confidence.


20

What’s New

LO2: Cut and prepare edge materials.

Introduction:

Metals are formed into structures by assembling or connecting each member parts through the process of welding. Therefore, the materials of varied sizes and thickness are cut and shaped with specific measurement and dimension. In this activity, the student shall develop skills in cutting materials with oxy-acetylene and discover other cutting outfit.

What is it

Flame Cutting Procedure

Pre-heat flame is properly adjusted and as you have taken all the safety measures, you are ready to do the actual cutting. You may see how fast cutting goes, but drills and practices will build confidence.


21

Using the neutral pre-heat flame, heat the spot where you intend to start until the flame turns cherry red. The pre-heat flame should be held just above the metal surface so as to protect pre-heat holes against metal flow back from the pure cutting oxygen. It is also to keep the torch end away from the heat reflected by the metal surface.

The distance between the end of the pre-heat cones and the surface of the material being cut is known as the coupling distance. When cutting plates up to 76 mm (3 inches) thick and with Mapp ® gas, the coupling distance must be about 3.25mm (1/8”). For cutting, coupling distance should be increased to get more heat from the secondary flame cones. Materials (plates) over 305mm thick (12 inches) should cut using 19.9-31.8mm coupling distance.

Straight Cutting

The stinger is pure oxygen flow out of the center hole of the cutting tip.

Once it starts, it can continue The cut should travel fast enough through the metal so that the top edge does not melt.

22

Once the pre-heated spot is cherry red in color, the cutting oxygen lever should be slowly depressed. This allows the pure cutting oxygen to attack the metal, removing the metal by flame pressure and oxidation by allowing the cutting oxygen to flow out slowly, the spot will not be cooled by the fresh oxygen stream. Cooling could happen if a large gush of oxygen is blown on to the heated spot all at once. The visible oxygen cutting stream coming from the center hole of the tip when the cutting oxygen valve is opened is called the stinger.

Manual hand cutting of sheet cut starts with the torch drawn over the gloved hand. The welder must be comfortable and be free to move the torch along the line to be cut. It is a good idea for the welder to get into the position and practice the cutting movements a few times before lighting the torch.


Steady hands are required in manual oxy-acetylene cutting especially when even straight cuts are needed. Once the cut starts, the torch must be moved steadily in the direction of the cut.

22

Once the pre-heated spot is cherry red in color, the cutting oxygen lever should be slowly depressed. This allows the pure cutting oxygen to attack the metal, removing the metal by flame pressure and oxidation by allowing the cutting oxygen to flow out slowly, the spot will not be cooled by the fresh oxygen stream. Cooling could happen if a large gush of oxygen is blown on to the heated spot all at once. The visible oxygen cutting stream coming from the center hole of the tip when the cutting oxygen valve is opened is called the stinger.

Manual hand cutting of sheet cut starts with the torch drawn over the gloved hand. The welder must be comfortable and be free to move the torch along the line to be cut. It is a good idea for the welder to get into the position and practice the cutting movements a few times before lighting the torch.


Steady hands are required in manual oxy-acetylene cutting especially when even straight cuts are needed. Once the cut starts, the torch must be moved steadily in the direction of the cut.

23

Profile of Flame-cut Plates

The physics of a cut, as the cut progresses along a plate, records of what is happening during the cut which is preserved along both sides of the key. This record indicates to the welder what is correct or incorrect with the pre-heat flame cutting speed and oxygen pressure.

Bevel Cutting

24

When bevel cutting is required, the torch head must be inclined in the position to the preheated metal along the top edge of the parts. This allows the metal to form the required bevel angle. The tip should be kept high enough so that the outlet holes are away from any splashing molten metals. Bevel cuts in the production are usually done by a radiograph. This produces a more accurate cut with less gas.

Position the four pre-heat holes A bevel cut made by for a fixed cut. oxy-acetylene cutting

Other cutting equipment/machines for plates and pipes

After performing task on oxy-acetylene and fuel gas cutting, there are other designed for cutting equipment/machines that produces mass cutting of materials at the largest welding production segment in the workplace the illustration/drawing showed, the cutting machines with work descriptions for the students to comprehend more.

Portable flame-cutting machine

A machine cutting torch sometimes referred to as a flow pipe operates in a similar manner to a hand cutting torch. The machine cutting torch may require two oxygen regulators, one for each. Pre-heat the oxygen and the other for the cutting oxygen stream. The addition of a separate cutting oxygen supply allows the flame to be more accurately adjusted. It also allows pressure to be charged during a cut without disturbing the other parts of the flame.

24

When bevel cutting is required, the torch head must be inclined in the position to the preheated metal along the top edge of the parts. This allows the metal to form the required bevel angle. The tip should be kept high enough so that the outlet holes are away from any splashing molten metals. Bevel cuts in the production are usually done by a radiograph. This produces a more accurate cut with less gas.

Position the four pre-heat holes A bevel cut made by for a fixed cut. oxy-acetylene cutting

Other cutting equipment/machines for plates and pipes

After performing task on oxy-acetylene and fuel gas cutting, there are other designed for cutting equipment/machines that produces mass cutting of materials at the largest welding production segment in the workplace the illustration/drawing showed, the cutting machines with work descriptions for the students to comprehend more.

Portable flame-cutting machine

A machine cutting torch sometimes referred to as a flow pipe operates in a similar manner to a hand cutting torch. The machine cutting torch may require two oxygen regulators, one for each. Pre-heat the oxygen and the other for the cutting oxygen stream. The addition of a separate cutting oxygen supply allows the flame to be more accurately adjusted. It also allows pressure to be charged during a cut without disturbing the other parts of the flame.

25

Flow Pipe

A cutting machine can make several complex cuts at one time. Automatic torches are set the same for pre-heating as the manual torches. However, the motor drives the automatic torch along the line of cut at the speed it could easily regulated by a variable control mechanism.

When the starting point on the joint is cherry red, the cutting oxygen is engaged for a continuous flow of oxygen. Then, the torch travel running mechanism is moved at a speed necessary for a smooth key edge. The torch head on most automatic cutting torches can be tilted to several angles for marking different bevel cuts. Using these machines, many different and complex cuts are made evenly.

Radius rods are also available for automatic cutting torches for circle cutting. Multiple cutting heads are commonly used for automatic cutting machines, especially where many pieces of the same shape are required.

Plasma Cutting Equipment

26

Plasma is a gas that has been heated to a high temperature and converted (ionized) so that the gas becomes electrically conductive. The plasma cutting process uses this plasma to transfer an electric arc to the metal. The metal is heated to the melting point by the heat of the arc and is blown away by air.

Parts of Plasma Arc cutters

➢ Power cables that works for 210-220 volts. ➢ The work table. ➢ Torch with head cable ➢ Air supply regulator valve.

The plasma torch tip has several openings. These openings help operate the torch. (A) Shows how air keeps the torch on each side of the metal cool and keeps the hot metal from spattering. (B) Allows the air to enter when the arc struck between the metal and the electrode is producing a pilot arc. When the tip is brought close to gas, it produces a stiff constricted cutting arc. This delivers a high concentration of heat to a very small area.

26

Plasma is a gas that has been heated to a high temperature and converted (ionized) so that the gas becomes electrically conductive. The plasma cutting process uses this plasma to transfer an electric arc to the metal. The metal is heated to the melting point by the heat of the arc and is blown away by air.

Parts of Plasma Arc cutters

➢ Power cables that works for 210-220 volts. ➢ The work table. ➢ Torch with head cable ➢ Air supply regulator valve.

The plasma torch tip has several openings. These openings help operate the torch. (A) Shows how air keeps the torch on each side of the metal cool and keeps the hot metal from spattering. (B) Allows the air to enter when the arc struck between the metal and the electrode is producing a pilot arc. When the tip is brought close to gas, it produces a stiff constricted cutting arc. This delivers a high concentration of heat to a very small area.

27

What I Have Learned

SELF-CHECK #2.1

Directions:

Use the checklist below as basis for judging whether you meet the required competency? Write YES or NO as your answer in a separate sheet.

YES NO

1. Can adjust pre-heat flame correctly.

2. Can heat the spot and recognize the cherry red color.

3. Can adjust cutting coupling distance based on thickness of metals to be cut.

4. Can start hand-cut with the torch drawn over the gloved hand.

5. Can move free and comfortably while cutting.

6. Can cut bevel by using correct angle.

7. Can check cutting outfit before cutting.

28

What I can do

Performance Criteria Checklist 2.1

OPERATION SHEET 2.1

Title: Cut and prepare edge materials.

Performance Objective: Given the following tools, materials equipment, you should be able to cut and prepare edge materials following the WPS standards in 2 hours.

Tools/Materials: • Steel plate • Goggles • Gloves • Chalk stone • Try Square • Push Pull Role

Equipment: Oxy Acetylene with accessories

Steps/Procedure: 1. Wear Proper Personal Protective Equipment (PPE) 2. Perform proper preparation technique 3. Perform standard Procedures in cutting of plate. 4. Perform and observe proper used of oxy-acetylene and its accessories. 5. Perform cutting of plate and beveling the plate.

Assessment Method: DEMONSTRATION

CRITERIA Did you…. YES NO

1. Wear Proper Personal Protective Equipment (PPE)

2. Perform proper preparation technique

3. Perform standard Procedures in cutting of plate.

4. Perform and observe proper used of oxy-acetylene and its accessories.

5. Perform cutting of plate and beveling the plate.

28

What I can do


OPERATION SHEET 2.1

Title: Cut and prepare edge materials.

Performance Objective: Given the following tools, materials equipment, you should be able to cut and prepare edge materials following the WPS standards in 2 hours.

Tools/Materials: • Steel plate • Goggles • Gloves • Chalk stone • Try Square • Push Pull Role

Equipment: Oxy Acetylene with accessories

Steps/Procedure: 1. Wear Proper Personal Protective Equipment (PPE) 2. Perform proper preparation technique 3. Perform standard Procedures in cutting of plate. 4. Perform and observe proper used of oxy-acetylene and its accessories. 5. Perform cutting of plate and beveling the plate.



1. Wear Proper Personal Protective Equipment (PPE)

2. Perform proper preparation technique

3. Perform standard Procedures in cutting of plate.

4. Perform and observe proper used of oxy-acetylene and its accessories.

5. Perform cutting of plate and beveling the plate.

29

What I Need to Know

Assessment Criteria:

1. Electrodes are well maintained and preserve according to industry standard. 2. Consumable gasses are specified and controlled in accordance with the job

requirements. 3. Electrodes are selected in accordance with the job requirements.


Learning Outcome 3: List of Welding Consumables Learning Activities Special Instructions 1. Read the attached information sheet # 3.1

and know to prepare weld consumables. 2. Answer the self-check # 3.1 to test your

knowledge on preparing and selecting weld consumables.

3. Compare your answer on answer key. 4. If you missed some items, go over this

enabling objective again. 5. When you are ready, you can proceed to

the next enable objective.


LO - 3 List of Welding Consumables

30

INFORMATION SHEET # 3.1

What’s New

LO3. List of Weld Consumables

Introduction:

All welding consumables used in the welding production will be maintained and controlled to remain, then supplies sound and acceptable. Handling of various electrode types and different gasses used in welding fabrication and production that requires critical post weld inspection needs special attention in performing task, like how to prepare these consumables in order to produce quality and acceptable welds. Electrodes are also selected correctly in accordance with electrode specification and welding procedure requirements. Therefore, the student/welder will have to develop their skills and knowledge on the maintenance and control of all consumables, as well as, the correct choice of using them.

Some recommended acceptable practices for the maintenance, selection and control of welding consumables are presented.

What Is It

Baking/Drying oven

Source: http://img.directindustry.com/image_di/photo-g/welding-electrode-drying-and-storage-oven-476384.jpg

Welding production and fabricators that usually accepts welding jobs are under the weld code provisions. First and foremost is to come out with a standard plan for electrode control and maintenance. Electrodes are kept in the stockroom for quite some time because of the influence of atmospheric conditions. These electrodes have to pass to drying or baking process. All electrodes for baking will be removed from a sealed plastic and will be placed inside the oven in a classified manner (based on types and diameter size of the electrode) through the oven shelves and marked accordingly. After loading, set the drying oven temperature from 2000 C – 3000 C maintaining the temperature for a period of two hours. Once the maximum of drying (2 hours) is reached shut-off the oven.


30

INFORMATION SHEET # 3.1

What’s New


Introduction:

All welding consumables used in the welding production will be maintained and controlled to remain, then supplies sound and acceptable. Handling of various electrode types and different gasses used in welding fabrication and production that requires critical post weld inspection needs special attention in performing task, like how to prepare these consumables in order to produce quality and acceptable welds. Electrodes are also selected correctly in accordance with electrode specification and welding procedure requirements. Therefore, the student/welder will have to develop their skills and knowledge on the maintenance and control of all consumables, as well as, the correct choice of using them.

Some recommended acceptable practices for the maintenance, selection and control of welding consumables are presented.

What Is It

Baking/Drying oven

Source: http://img.directindustry.com/image_di/photo-g/welding-electrode-drying-and-storage-oven-476384.jpg

Welding production and fabricators that usually accepts welding jobs are under the weld code provisions. First and foremost is to come out with a standard plan for electrode control and maintenance. Electrodes are kept in the stockroom for quite some time because of the influence of atmospheric conditions. These electrodes have to pass to drying or baking process. All electrodes for baking will be removed from a sealed plastic and will be placed inside the oven in a classified manner (based on types and diameter size of the electrode) through the oven shelves and marked accordingly. After loading, set the drying oven temperature from 2000 C – 3000 C maintaining the temperature for a period of two hours. Once the maximum of drying (2 hours) is reached shut-off the oven.


31

Holding oven

Source: http://www.rodovens.com/photos/ovens/k-450.jpg

After drying, remove the electrodes from the oven and store them in the storing oven with

a maintained temperature of 1500 C plus/minus 200 C. The electrode must stay from the oven without reducing the temperature as per requirement. The electrodes are maintained and controlled under the supervision of a storekeeper, as he is responsible for the issuance of these electrodes to the welders and fitters.

Portable oven

Source: http://www.antasweld.com/Upload/Picfiles/2009.12.13_7.9.36_9747.jpg

Normally welders perform welding activities in the shop. In cases where welding should

be done on a worksite, he should provide himself with a portable oven sometimes called welder’s oven. The welder’s oven should be plug to a power source. The temperature that should be maintained is 700 C plus/minus 100 C. The unused electrodes shall be returned to the storing oven after the end of day’s work.

32

Types of Electrodes, Diameter size, Current (amp) and Power Source

Mild Steel Electrodes

Electrodes Diameter Size Current Power Source E-6010 3.25 mm. 90 A – 120 A DC + E-6013 3.25 mm. 90 A – 120 A AC, DC + E-6011 3.0 mm. 80 A – 110 A AC, DC + E-6012 3.0 mm. 80 A – 110 A AC, DC -

Low Hydrogen Electrodes

E-7015 3.25 mm. 90 A – 110 A DC + E-7016 3.25 mm. 110 A – 130 A AC, DC + E-7018 3.25 mm. 110 A – 130 A AC, Dc +

Stainless Steel Electrodes

E-308 -16 3.25 mm. 90 A – 110 A AC, DC + E-316-15 3.0 mm. 80 A – 90 A DC+ E-316-15 3.25 mm. 90 A – 110 A DC + E-310-16 3.0 mm. 80 A - 90 A AC, DC +

Low Alloy Steel Electrode

E- 8018 3.25 mm. 110 A -130 A AC, DC + E-9016 4.0 mm. 140 A – 180 A AC, DC + E-9015 3.25 mm. 110 A – 130 A DC + E-8016 3.0 mm. 90 A – 110 A AC, DC +

Different types of electrodes, size, current, and power source are the recommendable data for electrodes that can be the basis for selection. Only four (4) types of electrodes are reflected in this information, but this will help you understand their proper use and their existing specification. Further studies and search of knowledge about electrodes, you will discover many things about welding consumables.

32

Types of Electrodes, Diameter size, Current (amp) and Power Source

Mild Steel Electrodes

Electrodes Diameter Size Current Power Source E-6010 3.25 mm. 90 A – 120 A DC + E-6013 3.25 mm. 90 A – 120 A AC, DC + E-6011 3.0 mm. 80 A – 110 A AC, DC + E-6012 3.0 mm. 80 A – 110 A AC, DC -

Low Hydrogen Electrodes

E-7015 3.25 mm. 90 A – 110 A DC + E-7016 3.25 mm. 110 A – 130 A AC, DC + E-7018 3.25 mm. 110 A – 130 A AC, Dc +

Stainless Steel Electrodes

E-308 -16 3.25 mm. 90 A – 110 A AC, DC + E-316-15 3.0 mm. 80 A – 90 A DC+ E-316-15 3.25 mm. 90 A – 110 A DC + E-310-16 3.0 mm. 80 A - 90 A AC, DC +

Low Alloy Steel Electrode

E- 8018 3.25 mm. 110 A -130 A AC, DC + E-9016 4.0 mm. 140 A – 180 A AC, DC + E-9015 3.25 mm. 110 A – 130 A DC + E-8016 3.0 mm. 90 A – 110 A AC, DC +

Different types of electrodes, size, current, and power source are the recommendable data for electrodes that can be the basis for selection. Only four (4) types of electrodes are reflected in this information, but this will help you understand their proper use and their existing specification. Further studies and search of knowledge about electrodes, you will discover many things about welding consumables.

33

The industrial gases must be stored in a separate storage room and must have proper air ventilation. The place should be equipped with fire hazard signs and also a unit of fire extinguisher to be installed in location near the series of filled full tanks for accessibility. Cylinders must be provided with protection caps to prevent the valves from being broken. Defective tanks, fitters and others must be separated and marked defective.

Leaking fuel gas cylinders should be out of the building. Place the cylinders in an open space and put a danger sign. Slowly release the pressure until the gas is totally removed.

34

Welding Electrodes

E - stands for electrode and is used for electric arc welding.

The first two or first three-digit numbers designate the tensile strength of a metal in thousands of pounds

The next digit means welding position. If it is:

1 - All position

2 - In Flat and Horizontal position

3 - Vertical down

34

Welding Electrodes

E - stands for electrode and is used for electric arc welding.

The first two or first three-digit numbers designate the tensile strength of a metal in thousands of pounds

The next digit means welding position. If it is:

1 - All position

2 - In Flat and Horizontal position

3 - Vertical down

35

The last digit indicates the type of coating and the polarity of the electrode.

Various electrode rating and its respective polarity.

36

What I Have Learned

Self-Check # 3.1


Directions:

Choose the correct answer from the series given for every item. Write the letter only. Use a separate answer sheet.

1. An electrode oven with a maintaining temperature of 700 C +/- 10. a. Drying oven c. Portable oven b. Holding oven d. Heating oven

2. An oven which holds a temperature of 1500 C +/- 20.

a. Holding oven c. Heating oven b. Portable oven d. Baking oven

3. Mild steel electrode.

a. E–316-15 c. E-9015 b. E-7018 d. E-6013

4. Low alloy electrode.

a. a. E-316-16 c. E-7015 b. b. E-9016 d. E-6012

5. To prevent the cylinder valves from breaking down, these should be provided with:

a. a. Cover c. Wrap with a chain b. b. Protective caps d. Hazard sign

36

What I Have Learned

Self-Check # 3.1


Directions:

Choose the correct answer from the series given for every item. Write the letter only. Use a separate answer sheet.


2. An oven which holds a temperature of 1500 C +/- 20.

a. Holding oven c. Heating oven b. Portable oven d. Baking oven

3. Mild steel electrode.

a. E–316-15 c. E-9015 b. E-7018 d. E-6013

4. Low alloy electrode.

a. a. E-316-16 c. E-7015 b. b. E-9016 d. E-6012

5. To prevent the cylinder valves from breaking down, these should be provided with:

a. a. Cover c. Wrap with a chain b. b. Protective caps d. Hazard sign

37

What I Need to Know


1. Surfaces and edges are clean based on the required specifications. 2. Equipment and tools are identified for having clean surfaces and edges. 3. Tasks are performed in accordance with the industry requirement and safety.


Learning Outcome 4: Clean surfaces and edges

Learning Activities Special Instructions 1. Read the attached information sheet # 4.1

and know to cut and prepare edge materials.

2. Answer the self-check # 4.1 to test your knowledge on cut and prepare edge materials.

3. Compare your answer on answer key 4. If you missed some items, go over this

enabling objective again. 5. When you are ready, you can proceed to

the next enable objective.


LO - 4 Clean Surfaces and Edges

38

What’s New

LO4. Preparation of weld surfaces and edges

Introduction:

Proper cleaning of metal surfaces and edges must be in mind before any fit-up and tacking took placed. There must be an acceptable cleaning procedure applied in the surface of the plates and pipes before welding joints. The cleaning of surfaces and edges is considered one step for achieving quality on the preparation of materials.

Below are acceptable practices in the preparation of surfaces and edges of the materials.

What Is It

Illustration: Figure 1

Edge A need to grind smoothly and squarely so that no gaps appear on the fit-up and the surface of the other plate to form Tee-joint. These two sides of the plate are placed together and see to it that no gaps are found, then tightly assemble. The contaminants that are found in the fit-up must be cleaned and removed for welding safety.


38

What’s New

LO4. Preparation of weld surfaces and edges

Introduction:

Proper cleaning of metal surfaces and edges must be in mind before any fit-up and tacking took placed. There must be an acceptable cleaning procedure applied in the surface of the plates and pipes before welding joints. The cleaning of surfaces and edges is considered one step for achieving quality on the preparation of materials.

Below are acceptable practices in the preparation of surfaces and edges of the materials.

What Is It

Illustration: Figure 1

Edge A need to grind smoothly and squarely so that no gaps appear on the fit-up and the surface of the other plate to form Tee-joint. These two sides of the plate are placed together and see to it that no gaps are found, then tightly assemble. The contaminants that are found in the fit-up must be cleaned and removed for welding safety.


39

Safety measures:

Before tacking, air tight fit-up must be checked so as to avoid air pockets in the fitted edge or surface.

The drawing showing Fig. A and B plates are beveled cut. The gas cutting results are not properly done, the surface is not smooth and with irregular line cut caused by incorrect cutting. The surface must be smoothened with the use of a grinder until such appearance is accepted. The surface of any dirt and contaminants such as rust, oil, grease, water, scale and old paint must be removed with appropriate tools and solution.

After root face is made and smoothened on the beveled surface, the two plates are placed together facing each other with an approximate gap before tacking may be done. This kind of preparation is applicable for plates and pipes for the different types of materials. The root face must not exceed the maximum of 3mm thick from wall thickness of 6mm to 20 mm.

40

What I Have Learned

SELF-CHECK # 4.1

LO4. Clean surfaces and edges.

Directions:

Chose the letter of the correct answer. Use separate answer sheet.

1. Why do cleaning of surface and edges of metal so important?

a. Provide good appearance of the cut material b. Obey because it was instructed to do so. c. Dirt and other substance detrimental to weld quality. d. Very easy to fit-up joint.

2. Removal of metal scales, old points, rust in metal is easy with the use of:

a. Grinder b. Scraper c. Chipping hammer d. Metal sand paper

3. Why air tight fit-up necessary for Tee-joint preparation?

a. Dirt or contaminant will not stock inside b. Avoid gas pockets associated from the unfit fit-up. c. Rust attacked easily d. None of the above

4. Beveled joint is considered “critical” in the category of weld. This means that:

a. Weld joint is necessary for radiography b. Weld joint is for visual c. Weld joint with no inspection d. All of the above.

5. Root face of beveled joint will not exceed a maximum of:

a. 3 mm b. 5 mm c. 3 mm d. 6 mm

40

What I Have Learned

SELF-CHECK # 4.1

LO4. Clean surfaces and edges.

Directions:

Chose the letter of the correct answer. Use separate answer sheet.

1. Why do cleaning of surface and edges of metal so important?

a. Provide good appearance of the cut material b. Obey because it was instructed to do so. c. Dirt and other substance detrimental to weld quality. d. Very easy to fit-up joint.

2. Removal of metal scales, old points, rust in metal is easy with the use of:

a. Grinder b. Scraper c. Chipping hammer d. Metal sand paper

3. Why air tight fit-up necessary for Tee-joint preparation?

a. Dirt or contaminant will not stock inside b. Avoid gas pockets associated from the unfit fit-up. c. Rust attacked easily d. None of the above

4. Beveled joint is considered “critical” in the category of weld. This means that:

a. Weld joint is necessary for radiography b. Weld joint is for visual c. Weld joint with no inspection d. All of the above.

5. Root face of beveled joint will not exceed a maximum of:

a. 3 mm b. 5 mm c. 3 mm d. 6 mm

41

What I can do



1. Wear standard PPE’s

2. Prepare materials to be clean.

3. Conduct proper cleaning of surface and edges.

4. Perform grinding on rough and uneven surface for smooth preparation.

5. Check for the job completeness

TASK SHEET 4.1

Title: Preparation of weld surfaces and edges.

Performance Objective: Given the following tools, materials equipment, you should be able to Clean surface and edges following the WPS standards in 2 hours.

Tools/Materials: • Steel plate • goggles • Gloves • Steel brush • Grinding disc • Files • Sand paper

Equipment: Angle grinder

Steps/Procedure

1. Wear standard PPE’s 2. Prepare materials to be clean. 3. Conduct proper cleaning of surface and edges. 4. Perform grinding on rough and uneven surface for smooth preparation. 5. Check for the job completeness.


42

What I Need to Know


1. Personnel Protective Equipment (PPE) is applied in accordance with the occupational safety requirements.

2. Welding Safety practices and protective equipment are checked if in accordance with the safety standard.


Learning Outcome 5: Prepare Protective Welding Equipment


1. Read the attached Information Sheet No. 5.1 2. Answer the self-check No. 5.1 to test your

knowledge on how to prepare protective welding equipment.


enabling objective again. 5. When you are ready, you can proceed to the

next enabling LO.


LO - 5 Protective Welding Equipment

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What I Need to Know


1. Personnel Protective Equipment (PPE) is applied in accordance with the occupational safety requirements.

2. Welding Safety practices and protective equipment are checked if in accordance with the safety standard.


Learning Outcome 5: Prepare Protective Welding Equipment


1. Read the attached Information Sheet No. 5.1 2. Answer the self-check No. 5.1 to test your

knowledge on how to prepare protective welding equipment.


enabling objective again. 5. When you are ready, you can proceed to the

next enabling LO.


LO - 5 Protective Welding Equipment

43

What’s New

LO5: Prepare Protective Welding Equipment

Introduction:

The general work clothing is worn by each person working in the shop. All of these clothing’s may not have frayed edges or holes. In addition to the clothing, extra protection is needed for each person who is in direct contact with the materials. Tongs and pliers are used in picking-up hot metals.

What Is It

Leather Jacket Leather Apron Welding Gloves Welding shield Face shield

Safety glasses Welding cap Safety boots Respirator Full-leather slaves


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Additional extra protection aside from general clothing are: leather jacket, apron, welding gloves, welding shield, face shield, safety gloves, welding cap, safety boots, respirators, and full leather sleeves. Full clothing protection will practically protect the whole body of the welder.

For your safety, it is proper to know the uses of your protective gadgets while working with metals.

• Safety is a reminder to anticipate all of the precaution possible risk and danger in every welding job.

• Safety glass protects the eyes from weld sparks and always worn by worker in the shop. • Welding shield cover the face and allow welder to see legibly on weldment while

performing welding. • Face shield is a transparent hard plastic covering the eye while clearing and grinding. • Welding cap worn by welder as an additional safety for head and hair. • Respirator is an equipment that prevent us from fumes and odor from industrial waste. • Leather apron a front body protection device while welding. • Leather jacket worn by welder during welding difficult position. • General clothing the usual personal clothing of a welder such as over-all, welding apron

or welding jackets • Safety Gloves worn by welders to protect the hands in heat and burns. • Welding Goggles protective glasses set in a flexible frame that fit snugly against the

face. • Welding shoes is made of chrome leather and protects our feet from spattering.

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Additional extra protection aside from general clothing are: leather jacket, apron, welding gloves, welding shield, face shield, safety gloves, welding cap, safety boots, respirators, and full leather sleeves. Full clothing protection will practically protect the whole body of the welder.

For your safety, it is proper to know the uses of your protective gadgets while working with metals.

• Safety is a reminder to anticipate all of the precaution possible risk and danger in every welding job.

• Safety glass protects the eyes from weld sparks and always worn by worker in the shop. • Welding shield cover the face and allow welder to see legibly on weldment while

performing welding. • Face shield is a transparent hard plastic covering the eye while clearing and grinding. • Welding cap worn by welder as an additional safety for head and hair. • Respirator is an equipment that prevent us from fumes and odor from industrial waste. • Leather apron a front body protection device while welding. • Leather jacket worn by welder during welding difficult position. • General clothing the usual personal clothing of a welder such as over-all, welding apron

or welding jackets • Safety Gloves worn by welders to protect the hands in heat and burns. • Welding Goggles protective glasses set in a flexible frame that fit snugly against the

face. • Welding shoes is made of chrome leather and protects our feet from spattering.

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What I Have Learned

SELF-CHECK # 5.1

LO5. Protective Welding Equipment

Directions:

Read the instruction carefully. Match column A with column B. Write the letter of the correct answer on the blank provided before the number. Use separate answer sheet.

Column A Column B

_____ 1. Face shield

_____ 2. Respirators

_____ 3. Leather Jacket

_____ 4. Welding cap

_____ 5. Welding shield

_____ 6. Leather apron

_____ 7. Safety gloves

_____ 8. Safety boots

_____ 9. Full leather sleeves

_____ 10. Safety glass

a. Hand protective device during welding. b. Head and hair protection while welding. c. Feet and legs protection d. Worn always in shop during tour of duty. e. Additional protection that covers body

and shoulder. f. Added protective device in front side of

the body. g. To be worn in the area with toxic fumes. h. Face and eyes protection. i. Use to protect eye and face while

grinding and cleaning weld. j. Shoulder legging sleeves. k. Picking hot metals.

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Assessment: (Summative-Test)

Directions:

Write the letter of the correct answer in every item. Provide a separate answer sheet.

1. Injection torches can use fuel gases with pressure as low as: a. 7 psi (0.49 kg/cm2) c. 6 oz./in2 (26.3 g/cm2) b. 2 psi (0.14 kg/cm2) d. 9 oz./in2 (39.4 g/cm2)

2. Oxygen and acetylene hoses should be color coded. Which of the given answers is correct?


3. It is considered as a line pressure gauge. a. Regulator b. Low pressure gauge c. High pressure gauge d. Valve gauge

4. A typical characteristic of a neutral flame is a. Acetylene and with excess Oxygen b. Balance of Acetylene and Oxygen c. Oxygen and with excess Acetylene d. Acetylene burning in the atmosphere

5. OFC is an acronym for: a. Oxy-fuel cutting c. Oxygen fueled cutting b. Oxy-fused cutting d. None of the above



8. An oven which holds a temperature of 1500 C +/- 20. a. Holding oven c. Heating oven b. Portable oven d. Baking oven

9. Which of the following electrodes is used in mild steel? a. E–316-15 c. E-9015 b. E-7018 d. E-6013

10. Which of the following electrodes is used in low alloy steel? a. E-316-16 c. E-7015 b. E-9016 d. E-6012 3

46

Assessment: (Summative-Test)

Directions:

Write the letter of the correct answer in every item. Provide a separate answer sheet.

1. Injection torches can use fuel gases with pressure as low as: a. 7 psi (0.49 kg/cm2) c. 6 oz./in2 (26.3 g/cm2) b. 2 psi (0.14 kg/cm2) d. 9 oz./in2 (39.4 g/cm2)

2. Oxygen and acetylene hoses should be color coded. Which of the given answers is correct?


3. It is considered as a line pressure gauge. a. Regulator b. Low pressure gauge c. High pressure gauge d. Valve gauge

4. A typical characteristic of a neutral flame is a. Acetylene and with excess Oxygen b. Balance of Acetylene and Oxygen c. Oxygen and with excess Acetylene d. Acetylene burning in the atmosphere

5. OFC is an acronym for: a. Oxy-fuel cutting c. Oxygen fueled cutting b. Oxy-fused cutting d. None of the above



8. An oven which holds a temperature of 1500 C +/- 20. a. Holding oven c. Heating oven b. Portable oven d. Baking oven

9. Which of the following electrodes is used in mild steel? a. E–316-15 c. E-9015 b. E-7018 d. E-6013

10. Which of the following electrodes is used in low alloy steel? a. E-316-16 c. E-7015 b. E-9016 d. E-6012 3

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11. To prevent the cylinder valves from breaking down, these should be provided with _____.

a. Covers c. Wraps with chains b. Protective caps d. Hazard sign

12. Why is cleaning of surface and edges of metal so important? a. It provides good appearance of the cut material b. For the sake of following instructions. c. Dirt and other substances are detrimental to weld quality. d. It makes it easy to fit-up joint.

13. Removal of metal scales, old paints and rust in metal is easy with the use of a: a. Grinder c. Chipping hammer b. Scraper d. Metal sand paper

14. Why is air tight fit-up necessary for Tee-joint preparation? a. Dirt or contaminant will not stock inside. b. It prevents gas pockets associated with unfit fit-up. c. Rust attacks metal easily. d. None of the above

15. Beveled joint is considered “critical” in the category of weld. This means that _____ a. Weld joint is necessary for radiography. b. Weld joint is for visual inspection. c. Weld joint with no inspection d. All of the above

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ANSWER KEY

ANSWER KEY

No. Self-Check 1.1

Self-Check 2.1 (OPRERATION)

Self-Check 3.1

Self-Check 4.1

Self-Check 5.1

1. C C C I 2. C A A G 3. B D B E 4. B B A B 5. A B A H 6. A F 7. A 8. C 9. J 10. D

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ANSWER KEY

ANSWER KEY

No. Self-Check 1.1

Self-Check 2.1 (OPRERATION)

Self-Check 3.1

Self-Check 4.1

Self-Check 5.1

1. C C C I 2. C A A G 3. B D B E 4. B B A B 5. A B A H 6. A F 7. A 8. C 9. J 10. D

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References:

"How to Strike and Establish an Arc | Lincoln Electric Canada." Lincolnelectric. Accessed January 28, 2020. https://www.lincolnelectric.com/en-ca/support/welding-how-to/Pages/strike-establish-arc-detail.aspx.

Jacob. "SMAW (Stick Welding)." SlideServe. Last modified January 23, 2012.

https://www.slideserve.com/jacob/smaw-stick-welding. JEFFUS, LARRY, and HAROLD JOHNSON. Welding Principles and Application. n.d. KENNEDY, GOWER A. Welding Technology 2nd Ed.. n.d. Kennedy, Gower A. Welding Technology, 1982 ed. Bobbs Merrill, n.d. RHONE, L. C. Total Auto Body Repair, 3rd Ed.. n.d. Welding Inspection Technology. Education Department, American Welding Society, n.d.

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