NOT

9
Technology and
Livelihood Education
Quarter 1, Wk.1-7 - Module 1
Prepare Weld Materials

Department of Education ● Republic of the Philippines

Technology and Livelihood Education- Grade 9 (SMAW)
Alternative Delivery Mode
Quarter 1, Wk.1 - 7 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 – Division of Iligan city

Schools Division Superintendent: Roy Angelo E. Gazo, PhD.,CESO V

Development Team of the Module

Writer: WIinstunjun N. Tuliao & Ranil R. Dasmariñas
Content Evaluators: James C. Guiuo & Edilberto B. Luzon
Illustrator/Layout Artist: WIinstunjun N. Tuliao & Ranil R. Dasmariñas
Management Team
Chairperson: Roy Angelo E. Gazo, PhD, CESO V
Schools Division Superintendent

Co-Chairpersons: Nimfa R. Lago, MSPh, PhD, CESE

Assistant Schools Division Superintendent

Members: Henry B. Abueva OIC-CID Chief

Blair D. Castillon, PhD., EPS-EPP/TLE
Sherlita L. Daguisonan, LRMS Manager
Meriam S. Otarra, PDO II
Charlotte D. Quidlat, Librarian II

Printed in the Philippines by

Department of Education – Division of Iligan City
Office Address: General Aguinaldo, St., Iligan City
Telefax: (063)221-6069
E-mail Address: [email protected]
9
Technology and
Livelihood
Education
SMAW
Quarter 1,Wk.1-7- Module 1
Module Title: Prepare Weld Materials

This instructional material was collaboratively developed and reviewed

by select teachers, school heads, and Education Program Supervisor in
EPP/TLE of the Department of Education - Division of Iligan City. We
encourage teachers and other education stakeholders to email their
feedback, comments, and recommendations to the Department of Education-
Iligan City Division at [email protected] or Telefax: (063)221-6069.

We value your feedback and recommendations.

Department of Education ● Republic of the Philippines

This page is intentionally blank
Table of Contents
Pages
What This Module is About................................................................................................. i
Recognition Prior Learning....................................................................................... ii
How to Learn from this Module.............................................................................................. iii
Icons of this Module............................................................................................................... iv
Diagnostic Test....................................................................................................................... v
Welding Terminologies…………………………………………………………………………....... vii

Learning Outcome # 1:Set-up cutting Equipment

Pretest………………………………………………………………………………………............. 1
Learning Experiences/Activities....................................................................................... 2
Information Sheet # 1.1........................................................................................................ 3
Task Sheet #1.1.................................................................................................................. 8
Self-Check # 1.1................................................................................................................. 15
Performance Criterion Checklist # 1.1………………………………………………………….. 16

Learning Outcome # 2: Cut and Prepare Edge of Materials

Pretest………………………………………………………………………………………………. 17
Learning Experiences/Activities...................................................................................... 18
Information Sheet #2.1.............................................................................. ………………… 19
Task Sheet #2.1................................................................................................................. 19
Self-Check #2.1................................................................................................................ 25
Performance Criterion Checklist # 2.1………………………………………………………….. 25
Operation sheet #2.2.................................................................................... ……………. 26
Performance Criterion Checklist # 2.2…………………………………………………………. 27

Learning Outcome # 3:Clean Surface and Edges

Pretest……………………………………………………………………………………………… 28
Learning Experiences/Activities………………………………………………………………… 39
Information Sheet # 3.1......................................................................…………………….. 30
Task sheet # 3.1…………………………………………………………………………………. 30
Self-Check # 3.1............................................................................................................... 32
Performance Criterion Checklist # 3.1………………………………………………………… 33
Operation sheet #3.2..................................................................................................... 33
Performance Criterion Checklist # 3.2………………………………………………………. 34

Learning Outcome # 4: Prepare Welding Consumables

Pretest……………………………………………………………………………………………. 35
Learning Experiences/Activities……………………………………………………………….. 36
Information Sheet #4.1..................................................................................................... 37
Task Sheet # 4.1………………………………………………………………………………… 43
Self-Check # 4.1................................................................................. ……………………. 44
Performance Criterion Checklist # 4.1………………………………………… 44
Learning Outcome # 5: Prepare Welding Protective Equipment
Pretest……………………………………………………………………………………………… 45
Learning Experiences/Activities..................................................................................... 46
Information Sheet # 5.1 ............................................................................... …………….. 47
Task Sheet # 5.1................................................................................................................ 48
Self-Check #5.1............................................................................................. …………….. 49
Performance Criterion Checklist # 1.1…………………………………………………………… 49

Summary…………………………………………………………………………………………….. 50
Summative Test…………………………………………………………………………................ 51
Key to Answers ...............................................................................................................….. 53
References .....................................................................................................................… 55
This page is intentionally blank
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.

Remember to:

 Work through all the information and complete the activities in each section.
 Read Information Sheets and complete the self-check. Suggested references are
included to supplement the materials provided in this module.
 Most probably, your trainer will also be your supervisor or manager. He is there to
support you and show you the correct ways to do things.
 You will be given plenty of opportunities’ to ask questions and practice on the job.
Make sure you practice your new skills during your regular work shifts. This way you
will improve your speed, memory and your confidence.
 Use the Self Checks, operation Sheets or Tasks Job Sheets at the end of each
Section to test your own progress. Use the performance criteria Checklist or
Procedural Checklist located after the Sheet to check your own performance.
 When you feel confident that you have had sufficient practice, asks your trainer to
evaluate you. The results of your assessment will be recorded in your Progress Chart
and Accomplishment Chart.

You need to complete this module before you can perform the next module.

i
What’s In

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.

ii
How to Learn from this Module
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_IAAW9-12WM-Ia-b-1
• LO2 Cut and prepare edge of materials TLE_IAAW9-12WM-Ic-d-2
• LO3 Clean surfaces and edges TLE_IAAW9-12WM-Ie-3
• LO4 Prepare weld consumables TLE_IAAW9-12WM-If-4
• LO5 Prepare protective welding equipment TLE_IAAW9-12WM-Ig-5

iii
Icons of this Module

What I Need to This part contains learning objectives that

Know 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 Activities designed to process what you

Learned 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.

iv
What I Know

Diagnostic Test
Direction: Encircle the letter of the correct answer in every item.

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?

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. 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

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.

7. An electrode oven with a maintaining temperature of 700 C +/- 10.

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

v
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

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

vi
Welding Terminologies

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
0
C – 300 0C.
13. LP Liquified Petroleum
14. MAPP(R) Methylacetylene Propadiene

vii
Lesson

1 SET UP CUTTING EQUIPMENT up

Cutting Equipment

What I Know
Pre-test
Direction: Encircle the letter of the correct answer

1. is a tall tank cylinder where oxygen gas is stored.

a. Acetylene hose c. Oxygen cylinder

b. Acetylene cylinder d. Oxygen hose

2. It measures the amount of pressure or force for the gas that flows or is released from the
cylinder.

a. Gauge c. Working pressure gauge

b. Safety release valve d. Cylinder pressure gauge

3. A type of hose wherein oxygen gas flows towards the directions of the torch body.

a. Oxygen cylinder c. Acetylene cylinder

b. Safety chain d. Oxygen hose

4. hold the forces on both sides of a diaphragm in balance.

a. Safety release valve c. Cylinder pressure gauge

b. Regulator d. Working pressure gauge

5. A tank of lesser height where acetylene gas is stored is called .

a. Acetylene cylinder c. Safety release valve

b. Oxygen cylinder d. Oxygen hose

1
What I Need to Know

Assessment Criteria:
 Set-up cutting equipment in conformity with the occupational health and safety
standards
 Check cutting equipment fittings, connection, and power source in accordance with
workplace procedure

Learning Experiences/Activities:
Learning Activities Special Instructions:
Pre-test is designed to find out what the
1. Answer Pre-Test students need more instruction on and what
they may already know.
The focus of this learning outcome provides
learners the ability to perform the following
2. Read the attached
learning domains:
 Information Sheet # 1.1
 Task sheet # 1.1  Cognitive Skill
 Psychomotor Skill
 Affective Skill
3. Assessment (Self-Check & This self- checked instrument will give the
Performance Criterion Checklist)
necessary data or information on how far you
 ISSC # 1.1
can fill in your learning gaps.
 TSPCC # 1.1
Answer key will definitely help you to check
4. Compare your answer with answer keys
your own capacity of learning
This statement will warn you to go back to your
5. If you failed to meet the 80% of previous learning competencies because it
equivalent passing standard, simply fill
seems that you are not yet ready for the next
necessary gaps that have not mastered
level of competency.
Post-test is designed to measure the amount of
6. At the end of this L.O. answer the post learning a student has acquired in a specific
test
subject.
Ladderized learning is harmonization of all
learning’s and training mechanisms that allow
7. If you pass to this learning competency, learners to progress between technical-
then proceed to the next LO
vocational and higher education programs, or
vice-versa.

2
Information Sheet 1.1

What’s New
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.

3
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 ty

6. pe of hose wherein acetylene gas flows towards the direction of the torch body.

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

8. 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.

4
1. Working Pressure gauge - Measures pressure gas that flows or is released from the
torch body to the nozzle or tip.

2. Cylinder Pressure gauge - A registered gas pressure found in the cylinder.

3. Safety release valve - Is made up of a small ball held tightly against a seat by a spring.

4. Gauges - Show the working pressure and the other indicates the magnitude of pressure in
the cylinder.

5. Regulators - Work by holding the forces on both sides of a diaphragm in balance.

A. Acetylene Cylinder Valve B. Oxygen Cylinder Valve

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.

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.

5
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.

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.

6
(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.

7
Task Sheet 1.1

What’s More

PROCEDURES IN SETTING-UP 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.

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

8
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

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

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

The reverse flow valve Tightening of the hose

is already attached to
the regulator before
attaching the
6. If the torch is a combination-type torch, attach the cutting head.

Attaching the torch flame pipe to the hose

9
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.

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

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.

Opening of cylinder valve to merge in the hose

10
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.

11
The oxygen valve near the hose connection must be opened, before the cutting
lever will work.

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
Oxy-acetylene
Thickness of Acetylene Oxygen flow
Tip # Pressure
metal (mm) Flow (cfh) (cfh)
Psi(kpa)
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

12
Where:
mm - millimeter cfh – cubic feet per hour psi – pounds per square inch
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

13
“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.

14
What I Know
Self-Check 1.1
Direction:
Encircle the letter of the correct answer

1. is a tall tank cylinder where oxygen gas is stored.

a. Acetylene hose c. Oxygen cylinder
b. Acetylene cylinder d. Oxygen hose

2. It measures the amount of pressure or force for the gas that flows or is released from the
cylinder.
a. Gauge c. Working pressure gauge
b. Safety release valve d. Cylinder pressure gauge

3. A type of hose wherein oxygen gas flows towards the directions of the torch body.
a. Oxygen cylinder c. Acetylene cylinder
b. Safety chain d. Oxygen hose

4. hold the forces on both sides of a diaphragm in balance.

a. Safety release valve c. Cylinder pressure gauge
b. Regulator d. Working pressure gauge

5. A tank of lesser height where acetylene gas is stored is called .

a. Acetylene cylinder c. Safety release valve
b. Oxygen cylinder d. Oxygen hose

15
Task Sheet 1.1

Performance Criterion Checklist 1.1

CRITERIA
YES NO
Did you….
1. Secure Oxygen and Acetylene cylinders to the cart or wall correctly?

2. Remove safety caps and crack cylinder valve properly?

3. Check all parts for any damage?

4. Attach regulators to cylinders securely?

5. Attach flow valves and hoses to the gas outlet?

6. Install the cutting tip?

7. Back-out the pressure regulating screw before opening
the cylinder valves?
8. Adjust the regulating screw to satisfy the working pressure
needed?
9. Set-up cutting outfit correctly ready for use?

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

16
Lesson

2 CUT AND PREPARE EDGE MATERIAL

up Cutting Equipment

What’s In

Not frequently, a welder has to cut metal for a repair job or prepare some fresh
stock for welding. Oxy-fuel cutting has stepped up to the task for more than a half century,
but today you have other choices to get the job done. Even grinders can cut metal.

Our past lesson will help us lead to new lessons to generate new ideas about how
to “Cut and Prepare Edge of Materials”.

What I Know

Pre-test
Direction: Read the statements carefully. Write the word TRUE if the
statement is correct and FALSE if the statement is wrong in the blanks before the
number.

_______________ 1. Metals are formed into structures by assembling or connecting each

member parts through the process of cutting.
_______________ 2. The distance between the end of the pre-heat cones and the surface
of the material being cut is known as coupling distance
_______________ 3. 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.
_______________ 4. Oxygen is a gas that has been heated to a high temperature and
converted (ionized) so that the gas becomes electrically conductive.
_______________ 5. A machine cutting torch sometimes referred to as a flow pipe
operates in a similar manner to a hand cutting torch.

17
What I Need to Know

Assessment Criteria:
 Cut materials according to specified
 Prepare edge of materials according to specified dimensions/specifications

LEARNING EXPERIENCES/ACTIVITIES

Learning Activities Special Instructions:

Pre-test is designed to find out what the
1. Answer Pre-Test students need more instruction on and what
they may already know.
The focus of this learning outcome provides
2. Read the attached learners the ability to perform the following
 Information Sheet # 2.1 learning domains:
 Tasks Sheet # 2.1  Cognitive Skill
 Operation sheet # 2.2  Psychomotor Skill
 Affective Skill
3. Assessment (Self-Check &
Performance Criterion Checklist) This self- checked instrument will give the
 ISSC # 2.1 necessary data or information on how far you
 TSPCC # 2.1 can fill in your learning gaps.
 OSPCC # 2.2
Answer key will definitely help you to check
4. Compare your answer with answer keys
your own capacity of learning
This statement will warn you to go back to your
5. If you failed to meet the 80% of previous learning competencies because it
equivalent passing standard, simply fill
seems that you are not yet ready for the next
necessary gaps that have not mastered
level of competency.
Post-test is designed to measure the amount of
6. At the end of this L.O. answer the post learning a student has acquired in a specific
test
subject.
Ladderized learning is harmonization of all
learning’s and training mechanisms that allow
7. If you pass to this learning competency, learners to progress between technical-
then proceed to the next LO
vocational and higher education programs, or
vice-versa.

18
Information Sheet 2.1

What’s New

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.

Task Sheet 2.1

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.

Using the neutral pre-heat flame, heat the spot where you intend to start until the

19
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.

20
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.

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

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.

21
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

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

21
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.

22
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.

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.

23
Plasma Cutting Equipment

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.

24
What I Have Learned
Self-Check 2.1

Direction:
Read the statements carefully. Write the word TRUE if the statement is correct and
FALSE if the statement is wrong in the blanks before the number.

_______________1. Metals are formed into structures by assembling or connecting each

member parts through the process of cutting.
_______________2. The distance between the end of the pre-heat cones and the surface of the
material being cut is known as coupling distance.
_______________3. 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.
_______________4. Oxygen is a gas that has been heated to a high temperature and
converted (ionized) so that the gas becomes electrically conductive.
_______________5. A machine cutting torch sometimes referred to as a flow pipe operates in a
similar manner to a hand cutting torch.

Task Sheet 2.1

What I Have Learned

Performance Ctiterion Checklist 2.1

Directions:Use the checklist below as basis for judging whether you meet the required
competency. Check if it is YES or NO.

Performance Indicator 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.

25
Note: Have learners assess their performance. For the criteria needing assistance,
provide the appropriate intervention/s.

Operation Sheet 2.2

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. Secure Oxygen and Acetylene cylinders to the cart or wall correctly.
3. Remove safety caps and crack cylinder valve properly.
4. Check all parts for any damage.
5. Attach regulators to cylinders securely.
6. Install the cutting tip.
7. Back-out the pressure regulating screw before opening.
the cylinder valves
8. Adjust the regulating screw to satisfy the working pressure needed.
9. Set-up cutting outfit correctly ready for use.
10. Adjust pre-heat flame correctly.
11. Heat the spot and recognize the cherry red color.
12. Adjust cutting coupling distance based on thickness of metals to be cut.
13. Adjust cutting coupling distance based on thickness of metals to be cut.
14. Start hand-cut with the torch drawn over the gloved hand.
15. Move free and comfortably while cutting.
16. Cut bevel by using correct angle.
17. Check cutting outfit before cutting.
18. Perform 5 S.

Assessment Method: DEMONSTRATION

26
What I Have Learned

Performance Criterion Checklist # 2.2

Directions:
Use the checklist below as basis for judging whether you meet the required
competency. Check if it is YES or NO.

CRITERIA
YES NO
Did you….

1. Wear Proper Personal Protective Equipment (PPE).

2. Secure Oxygen and Acetylene cylinders to the cart or wall correctly?

3. Remove safety caps and crack cylinder valve properly?

4. Check all parts for any damage?

5. Attach regulators to cylinders securely?

6. Attach flow valves and hoses to the gas outlet?

7. Install the cutting tip?

8. Back-out the pressure regulating screw before opening
the cylinder valves?
9. Adjust the regulating screw to satisfy the working pressure
needed?
10. Set-up cutting outfit correctly ready for use?

11. Adjust pre-heat flame correctly.

12. Heat the spot and recognize the cherry red color.
13. Adjust cutting coupling distance based on thickness of metals to be
cut.
14. Start hand-cut with the torch drawn over the gloved hand.

15. Move free and comfortably while cutting.

16. Cut bevel by using correct angle.

17. Check cutting outfit before cutting.

18. Perform 5 S.

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

27
Lesson

3 1 CLEAN SURFACES AND EDGE up

Cutting Equipment

What’s In

You must prepare edges for welding when parts and assemblies require certain
strength. To achieve full welding penetration, you must cut the edges of the metal. The
weld replaces the removed material and makes a complete bridge between the joining
parts. Edge preparation is only possible for certain weld types.

Our past lesson will help us lead to new lessons to generate new ideas about how
to “Prepare Welding Consumables”.

What I Know
Pre-test
Directions:
Choose the letter of the correct answer.
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 c. Chipping hammer
b. Scraper d. Metal and sandpaper
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 c. 3 mm
b. 5 mm d. 6 mm

28
What I Need to Know

Assessment Criteria:
 Clean surfaces and edges based on the job requirements
 Use correct tools and equipment for cleaning surfaces and edges in accordance with the job
requirements
 Use appropriate Personal Protective Equipment (PPE)
 Perform proper housekeeping (5S)

LEARNING EXPERIENCES/ACTIVITIES

Learning Activities Special Instructions:

Pre-test is designed to find out what the
1. Answer Pre-Test students need more instruction on and what
they may already know.
The focus of this learning outcome provides
2. Read the attached learners the ability to perform the following
 Information Sheet # 3.1 learning domains:
 Tasks Sheet # 3.1  Cognitive Skill
 Operation sheet # 3.2  Psychomotor Skill
 Affective Skill
3. Assessment (Self-Check &
Performance Criterion Checklist) This self- checked instrument will give the
 ISSC # 3.1 necessary data or information on how far you
 TSPCC # 3.1 can fill in your learning gaps.
 OSPCC # 3.2
Answer key will definitely help you to check
4. Compare your answer with answer keys
your own capacity of learning
This statement will warn you to go back to your
5. If you failed to meet the 80% of previous learning competencies because it
equivalent passing standard, simply fill
seems that you are not yet ready for the next
necessary gaps that have not mastered
level of competency.
Post-test is designed to measure the amount of
6. At the end of this L.O. answer the post learning a student has acquired in a specific
test
subject.
Ladderized learning is harmonization of all
learning’s and training mechanisms that allow
7. If you pass to this learning competency, learners to progress between technical-
then proceed to the next LO
vocational and higher education programs, or
vice-versa.

29
Information Sheet 3.1

What’s New

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.

Task Sheet 3.1

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.

30
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.

31
What I Have Learned

Self-Check 3.1
Directions:
Choose the letter of the correct answer.

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

32
Task Sheet 3.1

What I Have Learned

Performance Criterion Checklist 3.1
Directions:

Use the checklist below as basis for judging whether you meet the required
competency. Check if it is YES or NO.

Performance Standard YES NO

1. Can clean surfaces and edges based on job requirements
2. Can use correct tools and equipment for cleaning surfaces and edges in
accordance to job requirements.
3. Can Perform grinding on rough and uneven surface for smooth preparation

3. Can use appropriate Personal Protective Equipment or PPE.

4. Can perform proper housekeeping or 5S.

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

Operation Sheet 3.2

What I Can Do

TASK SHEET 3.1

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.

33
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. Clean surfaces and edges based on job requirements
4. Use correct tools and equipment for cleaning surfaces and edges in accordance
to job requirements.
5. Perform grinding on rough and uneven surface for smooth preparation
6. Perform proper housekeeping or 5S.
Assessment Method: DEMONSTRATION

What I Have Learned

Performance Criterion Checklist 3.2

CRITERIA
YES NO
Did you….

1. Wear standard PPE’s

2. Can prepare materials to be clean.

3. Can clean surfaces and edges based on job requirements

4. Can use correct tools and equipment for cleaning surfaces and edges
in accordance to job requirements.
5. Can perform grinding on rough and uneven surface for smooth
preparation.
6. Can perform proper housekeeping or 5S.

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

34
Lesson

4 1PREPARE WELDING CONSUMABLES

up Cutting Equipment

Whats In

In order to clean surface and edges in welding first, you must wipe
down the metal with Low VOC PRE or acetone, this will remove any oils or grease on the
surface. The next step is to remove any oxides on the surface of the metal. To do this use
stainless steel wool or a stainless wire brush on the area to be welded.

What I Know

Pre-test
Directions:
Choose the letter of the correct answer.

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. b. E-7018 d. E-6013

4. Low alloy electrode.

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

35
What I Need to Know

Assessment Criteria
 Identify welding electrodes according to classification and specifications
 Maintain and keep electrodes in electrode oven based on prescribed temperature
 Prepare specified consumable gases based on job requirements
 Select correct materials in accordance with job requirements

LEARNING EXPERIENCES/ACTIVITIES

Learning Activities Special Instructions:

Pre-test is designed to find out what the
1. Answer Pre-Test students need more instruction on and what
they may already know.
The focus of this learning outcome provides
2. Read the attached learners the ability to perform the following
 Information Sheet # 4.1 learning domains:
 Tasks Sheet # 4.1  Cognitive Skill
 Psychomotor Skill
 Affective Skill
3. Assessment (Self-Check &
Performance Criterion Checklist) This self- checked instrument will give the
 ISSC # 4.1 necessary data or information on how far you
 TSPCC # 4.1 can fill in your learning gaps.

Answer key will definitely help you to check

4. Compare your answer with answer keys
your own capacity of learning
This statement will warn you to go back to your
5. If you failed to meet the 80% of previous learning competencies because it
equivalent passing standard, simply fill
seems that you are not yet ready for the next
necessary gaps that have not mastered
level of competency.
Post-test is designed to measure the amount of
6. At the end of this L.O. answer the post learning a student has acquired in a specific
test
subject.
Ladderized learning is harmonization of all
learning’s and training mechanisms that allow
7. If you pass to this learning competency, learners to progress between technical-
then proceed to the next LO
vocational and higher education programs, or
vice-versa.

36
Information Sheet 4.1

What’s New

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.

Task Sheet 4.1

What Is It

Baking/Drying oven

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

37
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.

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

38
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.

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.

39
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.

40
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

41
The last digit indicates the type of coating and the polarity of the electrode.

Various electrode rating and its respective polarity.

42
What I Have Learned

Self-Check
Directions:
Choose the letter of the correct answer.

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. E-316-16 c. E-7015
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

43
Task Sheet 4.1

What I Have Learned

Performance Criterion Checklist

Directions:
Use the checklist below as basis for judging whether you meet the required
competency. Check if it is YES or NO.

Performance Standard YES NO

1. Can identify welding electrodes according to classification and
specifications.
2. Can maintain and keep electrodes an electrode oven based on prescribed
temperature.
3. Can prepare specified consumable gases based on job requirements.
4. Can select correct materials in accordance to job requirements.

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

44
Lesson

4 PROTECTIVE WELDING EQUIPMENT

Cutting Equipment

Whats In
In welding, using the correct consumable, or filler material, ensures a strong bond
between two metals. It is one of the four components to a weld along with the metal
being welded, the heat source, and the shield from the air.

Our past lesson will help us lead to new lessons to generate new ideas about “Protective
Welding Equipment”.

What I Know
Pre-test
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.

Column A Column B
1. Face shield a. Hand protective device during welding.
2. Respirators b. Head and hair protection while welding.
3. Leather Jacket c. Feet and legs protection
4. Welding cap d. Worn always in shop during tour of
duty.
5. Welding shield e. Additional protection that covers body
6. Leather apron and shoulder.
7. Safety gloves f. Added protective device in front side of
the body.
8. Safety boots g. To be worn in the area with toxic
9. Full leather sleeves fumes.
10. Safety glass 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.

45
What I Need to Know
Assessment Criteria:
 Prepare PPE in accordance with occupational health and safety standards
 Check welding protective equipment in accordance with safety procedures

LEARNING EXPERIENCES/ACTIVITIES

Learning Activities Special Instructions:

Pre-test is designed to find out what the
1. Answer Pre-Test students need more instruction on and what
they may already know.
The focus of this learning outcome provides
2. Read the attached learners the ability to perform the following
 Information Sheet # 5.1 learning domains:
 Tasks Sheet # 5.1  Cognitive Skill
 Psychomotor Skill
 Affective Skill
3. Assessment (Self-Check &
Performance Criterion Checklist) This self- checked instrument will give the
 ISSC # 5.1 necessary data or information on how far you
 TSPCC # 5.1 can fill in your learning gaps.

Answer key will definitely help you to check
4. Compare your answer with answer keys
your own capacity of learning
This statement will warn you to go back to your
5. If you failed to meet the 80% of previous learning competencies because it
equivalent passing standard, simply fill
seems that you are not yet ready for the next
necessary gaps that have not mastered
level of competency.
Post-test is designed to measure the amount of
6. At the end of this L.O. answer the post learning a student has acquired in a specific
test
subject.
Ladderized learning is harmonization of all
learning’s and training mechanisms that allow
7. If you pass to this learning competency, learners to progress between technical-
then proceed to the next LO
vocational and higher education programs, or
vice-versa.

46
Information Sheet 5.1

What’s New

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

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.

47
Task Sheet 4.1

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.

48
What I Have Learned

Self-Check
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.

Column A Column B
1. Face shield i. Hand protective device during welding.
2. Respirators j. Head and hair protection while welding.
3. Leather Jacket k. Feet and legs protection
l. Worn always in shop during tour of
4. Welding cap
duty.
5. Welding shield m. Additional protection that covers body
6. Leather apron and shoulder.
7. Safety gloves n. Added protective device in front side of
the body.
8. Safety boots o. To be worn in the area with toxic
9. Full leather sleeves fumes.
10. Safety glass p. Face and eyes protection.
i. Use to protect eye and face while
grinding and cleaning weld.
l. Shoulder legging sleeves.
m. Picking hot metals.

Task Sheet 5.1

What I Have Learned

Performance Criterion Checklist

Directions:
Use the checklist below as basis for judging whether you meet the required
competency. Check if it is YES or NO.

Performance Standard YES NO

1. Can prepare Personal Protective Equipment or PPE in accordance with the
occupational health and safety standards.
2. Can check welding protective equipment in accordance to safety procedures.

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

49
Summary:

This module allows new learners to discover the realm world of welding. Knowing what weld
material is, a complex state of safety and responsibility. Every welder has its own strategy on how
to prepare weld materials on his easiest way as possible. But our most concern is how safe we are
in dealing with this adversity in a workplace area. Cutting and preparing edge of materials is crucial
to neophyte welder to experience such misfortune in using such modernize cutting equipment.
There must be a manual operating procedure to help them guides their discomforts and doubts of
safety, most especially in using electrical and mechanical tools such as grinders, power hacksaw
and other highly volatile cutting equipment’s like oxyacetylene. So that’s why constant monitoring is
highly emphasized and occupational health and safety procedure must always be observed. Safe
environment means safe practice that ensures safe well-being of anyone in the immediate area.
Clear and safety expectation must always be set and communicated to everyone in an organization.

A welder must be responsible and accountable in terms of welding management and work ethics.
Welders discipline and perseverance is a counterpart of their success.

Welders on the other hand, should always follow proper protocol for their security. They should
always wear their complete gears (Physical Protective Equipment) for their own protection. Full
form of safety is staying alert for every task you do.

50
Summative Test

Direction: Encircle the letter of the correct answer in every item.

16. 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)

17. Oxygen and acetylene hoses should be color coded. Which of 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.

18. It is considered as a line pressure gauge.

a. Regulator
b. Low pressure gauge
c. High pressure gauge
d. Valve gauge

19. 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

20. OFC is an acronym for:

a. Oxy-fuel cutting c. Oxygen fueled cutting
b. Oxy-fused cutting d. None of the above

21. 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.

22. An electrode oven with a maintaining temperature of 700 C +/- 10.

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

51
23. An oven which holds a temperature of 1500 C +/- 20.
a. Holding oven c. Heating oven
b. Portable oven d. Baking oven

24. Which of the following electrodes is used in mild steel?

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

25. 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

26. 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

27. 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.

28. 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

29. 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

30. 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

52
Answer Key

Diagnostic Test/Summative Test

1. C 6. C 11. A
2. C 7. A 12. C
3. B 8. D 13. A
4. B 9. B 14. D
5. A 10.A 15. B

Lesson 1 Set-up cutting equipment

Pre-Test/Self-check 1.1
1. C 2. A 3. D 4. B 5. A

Task Sheet 1.2

Performance Criterion Checklist 1.2
(Key answers of this Performance Criterion Checklist 2.2 will depend upon on how far the
learner learned/understand the given scenario. There answers will be credited according to tone
and quality of what they have learned to the Task sheet 2.2)

Lesson 2 Cut and prepare edge of materials

Pre-Test/Self-check 2.1
1. False 2. True 3. True 4. False 5. True

Task Sheet 2.1

Performance Criterion Checklist 2.1
(Key answers of this Performance Criterion Checklist 2.1 will depend upon on how far the
learner learned/understand the given scenario. There answers will be credited according to tone
and quality of what they have learned to the Task sheet 2.2)

Operation Sheet 2.1

Procedure Criteria Checklist 2.1
(Key answer of this operation sheet 2.1 will depend upon the tone and quality of the learner’s
performance criterion checklist during their time of demonstration)

Lesson 3 Clean surfaces and edges

Pre-Test/Self-check 3.1
1. C 2. A 3. D 4. B 5. B

Task Sheet 3.1

Performance Criterion Checklist 3.1
(Key answers of this Performance Criterion Checklist 3.1 will depend upon on how far the learner
learned/understand the given scenario. There answers will be credited according to tone and quality
of what they have learned to the Task sheet 3.2)

Operation Sheet 3.1

Procedure Criteria Checklist 3.1
(Key answer of this operation sheet 3.1 will depend upon the tone and quality of the learner’s performance
criterion checklist during their time of demonstration)

53
Lesson 4 Prepare welding consumables
Pre-Test/Self-check 4.1
1. C 2. A 3. B 4. A 5. A

Task Sheet 4.1

Performance Criterion Checklist 4.1
(Key answers of this Performance Criterion Checklist 4.1 will depend upon on how far the learner
learned/understand the given scenario. There answers will be credited according to tone and quality
of what they have learned to the Task sheet 4.2)

Lesson 5 Prepare welding protective equipment

Pre-Test/Self-check 5.1
1. I 6. F
2. G 7. A
3. E 8. C
4. B 9. J
5. H 10. D

Task Sheet 5.1

Performance Criterion Checklist 5.1
(Key answers of this Performance Criterion Checklist 5.1 will depend upon on how far the
learner learned/understand the given scenario. There answers will be credited according to tone
and quality of what they have learned to the Task sheet 5.2)

54
References:

JEFFUS, LARRY, and HAROLD JOHNSON. Welding Principles and Application. n.d.

KENNEDY, GOWER A. Welding Technology 2nd Ed.. n.d.

RHONE, L. C. Total Auto Body Repair, 3rd Ed.. n.d.

Welding Inspection Technology. Education Department, American Welding Society, n.d.

55
For inquiries and feedback, please write or call:

DepEd Division of Iligan City

Office Address: General Aguinaldo, St., Iligan City
Telefax: (063)221-6069
E-mail Address: [email protected]

56