WLD 253

SMAW Certification Practice

3/8" Mild Steel (E6011)

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2

Index

Course Information

Visual Inspection Criteria

3

4

Math On Metal 5-7

Science on Steel 8-12

Worksheets:

Science on Steel

Quality Control and Performance

Qualification

13-19

Craftsmanship Expectations for Welding

Projects

20

Information Sheets:

• Plate Fit-up

• Root Pass Inspection and Inter Pass

Cleaning

• Bend Test Procedures

21-28

Welding Projects 29-32

Final Exam Information

33-36

Assessment Breakdown for the Course

37

This project was supported, in part,

by the

National Science Foundation Opinions expressed are those of the authors

And not necessarily those of the Foundation

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Course Assignments Reading

Welding Principles and Applications by Larry Jeffus.

Welding Codes, Standards, and Costs

Testing and Inspection of Welds

Welder Certification

ANSI/AWS D1.1 Structural Welding Code, Performance Qualification

Work Sheets

Quality Control

Performance Qualification

Welding Projects

3G Certification Preparation

4G Certification Preparation

Bend Test Procedures

Final Exam

Closed Book Test

Timeline

Open-entry, open-exit instructional format allows the student to work at his/her own pace. It’s

the student’s responsibility to complete all assignments in a timely manner within your pre-

scheduled time. See your instructor for assistance.

Outcome Assessment Policy

The student will be assessed on his/her ability to demonstrate the achievement of course

outcomes. The methods of assessment may include one or more of the following: oral or written

examinations, quizzes, written assignments, visual inspection techniques, welding tests, safe

work habits, task performance and work relations.

Grading criteria

The student's assessment will be based on the following criteria:

15% of grade is based on Safe work habits and shop practices

20% of grade is based on Completion of written and reading assignments

15% of grade is based on demonstrating professional work ethics

40% of grade is based on completion of welding exercises

10% of grade is based on final exam/project

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Visual Inspection Criteria

For

Welding Certification Tests

This section will familiarize the student with inspection criteria that will be applied to the

evaluation of his/her projects. PCC Welding Department utilizes the visual inspection

requirements set forth under the Welder Qualification Section in AWS D1.1 Code. The

following criteria are gathered from this source.

For further information regarding these terms see the supplemental information section on

Matt’s curriculum CD.

Summary of Visual Inspection Criteria for Welder Qualification

A. The test must be complete. The full length (6”) of the test plate will be visually

inspected. Use your run off tabs throughout the test to insure quality results at the start

and finish at both ends of the plates. All craters shall be filled to the full cross section

of the weld.

B. Reinforcement layer (cover pass) height shall be Flush to 1/8” (3 mm) above the

plate.

C. A reinforcement layer higher that 1/8” (3 mm) will not be accepted.

D. Weld width cannot exceed ¼” wider than original groove opening.

E. Weld shall merge smoothly with the base metal.

F. Weld must be free of porosity, slag inclusions, and/or cold lap.

G. Undercut shall not exceed 1/32 in. (1 mm).

H. Arc strikes outside of the weld area are NOT acceptable.

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Math

on

Metal

The Welding Fabrication Industry needs qualified welder fabricators who can deal with a

variety of situations on the job. This portion of the training packet explores mathematics

as it relates to industry requirements.

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Conversion between Celsius

And Fahrenheit—WLD 253

Name: ________________________________ Date: _______________________

(Refer to the Solving formulas and Order of Operations to remember how to substitute numbers

into formulas and calculate a solution)

F = Fahrenheit

C = Celsius

Formulas to use: F = 9/5 C + 32

C = (F – 32) ÷ 1.8 or C = 5/9 (F – 32)

Convert the following Celsius values to Fahrenheit temperatures:

Example: C = 200° F = 9/5 (200) + 32

F = 360 + 32

F = 392

1. C = 0°

2. C = 10°

3. C = 20°

4. C = 30°

5. C = 100°

6. C = 250°

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Convert the following Fahrenheit values to Celsius (metric) temperatures:

Example: F = 1000° C = (1000 – 32) ÷ 1.8 OR C = 5/9(1000-32)

C = 968 ÷ 1.8 C = 5/9(968)

C = 537.78 degrees C = 537.78 degrees

7. F = 400° (max. interpass temp.)

8. F = 200° (preheat plates)

9. F = 1600° (kindling temp)

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Science

on

Steel

The Welding Fabrication Industry needs qualified welder fabricators who can deal with a

variety of situations on the job. This portion of the training packet explores science as it

relates to industry requirements.

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Mild Steel E6011 Certification

Contents of this Packet

- Introduction

- Importance of Code Qualification

- Why Mechanical Properties Testing?

- AWS D1.1 Structural Welding Code – Steel

- Significance of Bend Testing

- Effect of the E6011 vs. E7018 Electrodes on Bend Test Results

- Tensile Testing and Charpy V-Notch Impact Testing

Introduction

This packet covers the welder certification using E6011 cellulosic electrodes (for WLD-253), and

E7018 low-hydrogen electrodes (for WLD-254) on mild steel plate per AWS D1.1 Structural

Welding Code – Steel. Although the E6011 and E7018 electrodes operate differently (as

discussed in previous science packets), the testing required for welder qualification per AWS

D1.1 are similar. E6011 is primarily an AC, deep-penetrating, all-position electrode, which uses

cellulose to provide gaseous shielding. This allows the welder to have a clear view of the

keyhole in open root welding. E7018 is a lime-based, iron-powder, low-hydrogen electrode,

which provides a slag as the primary source of shielding and high deposition rate.

Importance of Code Qualification

In all industries, there are applicable codes and standards to assure the quality, reproducibility,

and adequacy of welded joints. Depending upon the application, a welded joint may need certain

mechanical properties; for example, welds on bridges must pass tests for strength, tensile

ductility, bend ductility, and Charpy impact toughness. These codes are based on many years of

experience. Changes to codes are ongoing to reflect the dynamic changes that taking place in the

industry. There are many welding codes to ensure quality welding. For example, the following

is a list of only a few typical industries and governing codes for welding quality.

Pressure Vessels ASME Boiler and Pressure Vessel Code (Vol.

IX – Welding Qualifications

Pipe and Pipe Lines API Standard 1104; Standard for Welding

Pipelines and Related Facilities

Pressure Piping ASME Code for Pressure Piping B31

All Steel Structures AWS D1.1 Structural Welding Code – Steel

Buildings AISC Specification for Structural Steel

Buildings

Bridges AASHTO/AWS D1.5; Bridge Welding Code

Ships ABS Rules for Building and Classing Steel

Vessels

Sheet Metal AWS D9.1; Sheet Metal Welding Code

Automotive Frames ANSI/AWS D8.8; Specification for

Automotive Frame Weld Quality

Aircraft MIL-STD-1595A; Qualification of Aircraft,

Missile, and Aerospace Fusion Welders

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Why Mechanical Properties Testing?

In all codes for welded structures and pipe, various degrees of mechanical testing are performed

to assure the quality and integrity of the structure. This includes both procedure qualification and

welder qualification. For example, the procedure qualification for steel structures in accordance

with the AWS D1.5 Bridge Welding Code–Steel requires that certain welds undergo all-weld-

metal tensile testing, transverse-to-weld tensile testing, side bend testing, Charpy v-notch (CVN)

impact testing as well as non-destructive testing. Mechanical testing is very important because it

ensures that the welding procedure, welder qualification, consumables, and the resulting

metallurgy of the weld and heat-affected zone are acceptable in accordance to code requirements.

Although the procedure qualification per AWS D1.1 requires tensile tests, bend tests, CVN

impact tests, and others, the primary test for welder qualification is the bend test. This is because

bend testing is the single most comprehensive screening test for workmanship and welder

competence.

AWS D1.1 Structural Welding Code – Steel

When a structure is going to be built, the owner and contractor agree on the appropriate welding

code, which will be needed to govern the acceptability or rejection of structural welds being

fabricated. AWS D1.1 Structural Welding Code – Steel is devised to provide welded joints with

acceptable strength, ductility, and CVN impact toughness for the intended application, such as a

building, general construction, motorized vehicle, etc. AWS D1.1 provides a minimum level of

weld quality that must be achieved. AWS D1.1 provides both procedure qualification

requirements and welder qualification and certification requirements. The qualification and

certification tests for welders are specially designed to determine the welder’s ability to produce

sound welds routinely. To achieve these quality standards, the welder qualification and

certification provide the means to ensure acceptable welds.

Significance of Bend Testing

Of all the tests prescribed by different welding codes, the bend test provides the best and most

reliable measure of ductility of the entire weld joint, including the weld metal, heat-affected

zone, and unaffected base metal. Welder qualification tests in AWS D1.1 always specify bend

testing of welded joints. This is because the bend test is extremely sensitive to all types of

metallurgical problems associated with welding. For example, weld joints which have

inadequate ductility and fail the requirements of the bend test may be due to: (a) hydrogen

assisted cracking, (b) microfissuring due internal solidification cracking, (c) excessive slag

inclusions, (d) excessive porosity, (e) wrong filler metal, causing embrittlement, (e) wrong

welding parameters, causing embrittlement, and (f) other metallurgical factors affecting the

ductility of the weld joint.

There are three types of bend tests, (1) side bend, (2) face bend, and (3) root bend. Side bend

tests are generally required for welds that are greater than 3/8-inch thick for AWS D1.1 and over

½-inch thick for API-1104. For example, a 2-inch thick butt joint deposited by single-pass

electroslag welding could not be tested by face or root bend testing because the thickness is too

great for practical testing. However, a 2-inch thick butt joint can be machined to several 3/8-inch

thicknesses and tested by side bending.

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So, face and root bending are used to test the ductility of butt joints that are thinner than 3/8-inch.

Whether face bends, root bends, or both face and root bends specimens are required depends

upon the code used. In AWS D1.1 Structural Welding Code, both face and root bends are

required in most cases. The root bend test determines the adequacy of the root preparation and

soundness of the root portion of the weld joint. This is particularly important in open root

welding applications. Similarly, the face bend test determines the adequacy of the weld metal

deposited on the face of the joint. These specimens must be able to withstand bending strains

that are produced when a plunger forces a 3/8-inch thick welded specimen into a guided bend

fixture. The plunger, having a specified bend radius, forces the welded bend specimen into a die

in order to endure a specified amount of bending (or plastic deformation), that is required by the

code for structural applications. From Table 1, the plunger radius and plunger thickness increase

with increasing yield strength of the base metal being tested. Bending becomes more difficult

with increasing yield strength, because ductility decreases as the strength of the steel increases.

Thus, AWS D1.1 permits the bend radius required for welder qualification to increase with

increasing yield strength, as shown in Table 1.

Table 1 Specified Bending Parameters for Guided Bend Test for Steel Welds

in accordance with AWS D1.1 Structural Welding Code - Steel

Yield Strength

Of Base Metal

Plunger

Thickness

Plunger

Radius

Interior Die

Opening

Die Radius

50,000psi and

less

Over 50,000psi

to 90,000psi

90,000psi and

greater

1 ½”

2”

2 ½”

¾”

1”

1 ¼”

2 3/8”

2 7/8”

3 3/8”

1 3/16”

1 7/16”

1 11/16”

Furthermore, the bend test for steel welds is very sensitive to the presence of diffusible hydrogen

in the weld. Even if non-destructive testing shows a welded steel to be crack-free, the bend test

can activate the hydrogen cracking mechanism in steel welds which are susceptible to hydrogen

cracking. Thus, there are many metallurgical causes for lack of adequate ductility in a welded

structure, and the bend test is best suited to separate the “good” welds from the “bad” welds.

Effect of the E6011 vs E7018 Electrodes on Bend Test Results

Although the bend testing procedure for weld joints deposited by E6011 and E7018 electrodes

are similar, the electrode composition can greatly affect the results of the bend test. The reason

for the difference in bending performance is the hydrogen content of the electrodes. Because

E6011 is a high-hydrogen electrode, the chances of passing the bend test are reduced in the as-

welded condition, due to hydrogen-assisted cracking. Hydrogen-assisted cracking can occur

during the bend test and reduce ductility so much that the bend test fails to meet minimum

requirements. Since bending stresses and high hydrogen content can initiate hydrogen-assisted

cracking in the weld and heat-affected zone, the welds deposited with cellulosic electrodes are

much more susceptible to failing the bend test than similar welds deposited with low-hydrogen

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E7018 electrodes. To prevent bend failures, cellulosic electrodes should only be used to weld

low-carbon mild steels because reduced carbon and alloy content reduce the susceptibility to

hydrogen-assisted cracking. However, whenever cellulosic electrodes must be used with higher

carbon, higher strength steels, then preheating is vitally necessary to prevent hydrogen-assisted

cracking and to pass the bend test.

Some codes allow bend test specimens to be baked prior to welding. If this practice is permitted,

bend specimens have a much better chance to pass the bend test because baking allows hydrogen

to diffuse out of the specimen. However, most codes which deal with fracture-critical

applications do not allow baking of any test specimens prior to testing. For example, AWS D1.5

Bridge Welding Code forbids baking of any test specimens prior to testing. That is, welded

specimens must be tested in the as-welded condition. In this way, the test results will truly

reflect the anticipated performance in the field.

Tensile Testing and Charpy V-Notch Impact Testing For welder qualification in accordance with AWS D1.1, tensile testing and Charpy v-notch

(CVN) testing of the test weld are not required. However, in other codes, these tests are also

used for welder qualification (in addition to bend testing).

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Science on Steel Questions—WLD 253

Name: _____________________________ Date: ________________________

Read each question carefully and answer the following questions with complete sentences using

the material in the Science on Steel section.

1. What are codes primarily based upon?

2. List 5 welding codes that are in use today.

A.

B.

C.

D.

E.

3. Explain why mechanical testing is used today.

4. List 7 reasons why bend tests fail

5. If a metal has a yield strength of 65,000psi, what size plunger should be used?

6. What are the primary flux ingredients for the following electrodes:

E6011

E7018

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7. List 3 mechanical tests required by AWS D1.5 Bridge Welding Code.

A.

B.

C.

8. List three types of bend tests

A.

B.

C.

9. Define Plastic Deformation

10. How can one prevent hydrogen assisted cracking when welding higher strength steel with

cellulosic electrodes (E6011)?

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Quality Control—WLD 253

Name: _________________________ Date: _______________________

Directions:

Review the text book, Welding Principles and Applications and utilize that information to

complete the questions on this work sheet. Answer the questions using complete sentences, and

do not hesitate to reference other sections in the text to find an answer.

1. What are Codes and Standards?

2. Explain the difference between a welding qualification test and a procedure qualification

test.

3. What is the difference between Qualifying and Certifying?

4. Why are welding procedures established?

5. How does a welding procedure specification (WPS) and a procedure qualification record

(PQR) differ from one another?

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6. What might influence the selection of a particular code or specification for welding?

7. Who should witness the test welding being performed by a tentative WPS?

8. Define essential variables as it applies to welding procedure.

9. How do welding procedures and pre-qualified procedures differ?

10. What is the difference between a discontinuity and a defect?

11. List five types of destructive tests.

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12. Define tolerance as it applies to mechanical drawings?

13. Define:

• Preheat -

• Interpass Temperature –

• Post Heat -

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Performance Qualification—WLD 253

Name: ________________________ Date: _____________________

Directions

Reference the AWS D1.1 Structural Steel Welding Code and utilize the index to locate the

information to complete the questions on this work sheet. List the section where the answer is

obtained in the code. Answer the questions using complete sentences, and do not hesitate to

reference other sections in the text to find an answer

1. What are the dimensions for a structural fillet weld break and macro etch test plate in

accordance with AWS D1.1?

2. What is the difference among a qualified welder, welding operator, and a tack welder?

3. What are the dimensions for a test plate of limited thickness (all position) test in

accordance with AWS D1.1?

4. How is a fillet weld test inspected?

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5. When a 3/8" groove weld test has passed the visual inspection test and it is going to

be x-rayed, what portion of the test will be examined on the radiograph?

6. A welder originally passed a qualification test with an E6011; is s/he qualified to weld

with an E7018? Why or Why not?

7. What are the acceptance criteria for both visual and mechanical testing for a fillet

weld test?

8. What are the acceptances criteria for both visual and radiographic testing on a 3/8"

groove-welding test?

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Craftsmanship Expectations for Welding Projects

The student should complete the following tasks prior to welding.

1. Thoroughly read each drawing.

2. Make a cutting list for each project. Cut at least two project assemblies of metal at

a time. This will save a great amount of time.

3. Assemble the welding projects per drawing specifications.

4. Review the Welding Procedure portion of the prints to review welding parameter

information.

5. See the instructor for the evaluation.

Factors for grading welding projects are based on the following criteria: Metal Preparation Project Layout Post Weld Clean-up

Oxyacetylene Cut quality Accurate (+/- 1/16”) Remove Slag/Spatter

Grind all cut surfaces clean Limit waste Remove sharp edges

Example of a high quality weld

Weld Quality per AWS D1.1Welder Qualification VT Criteria Cover Pass

Reinforcement (groove welds) Flush to 1/8”

Fillet Weld Size See specification on drawing

Undercut 1/32” deep

Weld Contour Smooth Transition

Penetration N/A

Cracks None Allowed

Arc Strikes None Allowed

Fusion Complete Fusion Required

Porosity None Allowed

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Plate Fit-up

The plate preparation and fit-up process is an incredibly important part in the welding process

that is many times over looked. The following steps will insure proper fit up is obtained which is

the first step in a high quality weld.

Prepare plate with the track

burner and grind the welded

surfaces clean prior to fitting up

the plates.

Use Vise-Grips (11R’s) to clamp

the back strap to the beveled

plate. Ensure that there is no gap

between the two plates.

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Plate Fit-up

Space the two beveled plates apart

by ¼” using a spacer gage. Use

the Vise Grip’s to clamp the plates

together. Again, ensure that there

is no gap between the back strap

and the two beveled plate.

A ¼” spacer should fit at all points

in the root of the joint. An

excessively wide or too narrow of a

root opening will reduce weld

quality.

Place your project in the desired

position per the requirements on

the project drawing.

3G (Vertical Position)

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Root Pass Inspection and Inter Pass Cleaning

In according with AWS

D1.1, “the root of the weld

shall be inspected and there

shall be no evidence of

cracks, incomplete fusion, or

inadequate joint

penetration.” If one of these

items is present the weld will

be unacceptable.

Inter pass cleaning is a

must!

At PCC, inter pass cleaning

shall be completed with

hand tools only. This

emphasizes the need for

students to develop their

welding skills.

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Bend Test Procedure

For 3/8” Test Plate

Bend tests are used to determine the ductility and soundness of a weld joint. The test will allow

the welder to determine if she or he has obtained fusion in the weld joint. Use the following

procedure in preparing and bending your coupons.

1. Reference AWS D1.1 Structural Welding Code to determine the dimensional

layout of the bend coupons (use this diagram for all positions).

2. Flush back up strip off of the plate at the flushing station. See requirements on

drawing below.

3. Layout four 1 1/2” wide coupons and cut using the track burner. See the print

below. Do Not Bend coupons greater than 1 1/2” wide they will not fit in the

bend jig.

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4. Allow coupon to air cool. Do Not Quench!

5. Grind coupon’s smooth, ensuring grinding marks are going with the length of the

coupons and all edges are rounded.

6. Request permission from your instructor to use the bend test machine.

7. CAUTION: Keep hands and fingers clear when operating equipment.

Watts Bend Test Machine

8. Ensure guard is in the correct position. The coupons sometimes eject out the

end of the machine rapidly.

Guard

9. Place coupon in the machine taking care not to position your hands/fingers in the

way. Locate weld in the center of the die. Bend one coupon (from each plate) to

test the face and one to test the root.

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10. Actuate the machine by the lever on the topside and stand away from the end

where the coupon will exit.

11. Inspect the convex surface of the bend specimen for fusion type defects.

Reference AWS D1.1 Structural Welding Code for Acceptance

Criteria for Bend Tests.

Four bend samples are shown above. Left

to right are: face bend, root bend, side bend

and a face bend.

The bend samples shown above are different

in the radius that they were bent. This is a

requirement set forth by the code that is

being referenced. Be sure to check the code

to determine what is required.

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Helpful Hints 1. Be prepared to feel confident during your test. You need to have demonstrated

consistency during your practice tests. Repeat the practice tests as many times as

necessary to ensure confidence and consistent performance.

2. Be comfortable !!! Plan your test on a day that you know you will be at your best, well

rested and able to concentrate. Check your clothing, to be certain you are protected from

any stray sparks. Nothing breaks your concentration faster than getting burned or catching

on fire!

3. Check the condition of your cover lenses; make sure that you can see clearly.

4. Bring a flashlight so you may thoroughly inspect your inter pass cleaning. Clean the weld

thoroughly. Make sure your slag hammer and wire brush are in good condition.

5. Plan the weld carefully to avoid having to patch up low spots. Decide before you strike

the arc the size and location of the bead you are about to run. If the weld fill becomes

uneven, fix it immediately by filling in the low areas, don't wait until the flush layer or

cover pass.

6. Notify your fellow students in your area that you are testing; ask their cooperation in

avoiding any banging or movement of the booth area while you are welding.

7. Above all don't panic! Relax and take your time. Don't hold your breath! If at any time

you become uncomfortable stop and reposition.

8. If you can not see STOP. If you feel you are loosing control of the puddle STOP.

9. Do not over heat the plates. Allow the plates to air cool to 200 degrees before you attempt

to weld the cover passes.

10. See your instructor at anytime if you have a concern. Take a break as needed.

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E6010 Butt Joint- Single Vee (3G) Project #1 Welding Sequence

E6011-- Root Pass Single pass technique ensuring the weld metal is fusing into all three

pieces

E6011—Fill Use split bead technique with stringer beads ensuring even fill.

E6011—Finish Beads Use step technique.

______________________________________________________________________________

Successful completion of this project will require the student to complete two welds that meet

both visual testing requirements and bend test requirements set forth in AWS D1.1 Structural

Steel Welding Code.

VT Criteria Project #1 Project #2

Reinforcement

Undercut

Bead Contour

Cracks

Arc Strikes

Fusion

Porosity

Bend Test

Grade Date

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E6010 Butt Joint- Single Vee (4G) Project #2

Welding Sequence

E6011-- Root Pass Single pass technique ensuring the weld metal is fusing into all three

pieces

E6011—Fill Use split bead technique with stringer beads ensuring even fill.

E6011—Finish Beads Use step technique.

______________________________________________________________________________

High quality root pass

An example of a high quality cover pass.

Successful completion of this project will require the student to complete two welds that meet

both visual testing requirements and bend test requirements set forth in AWS D1.1 Structural

Steel Welding Code.

VT Criteria Project #1 Project #2

Reinforcement

Undercut

Bead Contour

Cracks

Arc Strikes

Fusion

Porosity

Bend Test

Grade Date

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Final Exam

This portion of the final exam is a closed book test. Consult with your instructor to determine

items that you may need to review. Complete the exam and write all answers on the answer

sheet provided. Once completed, return the exam and answer sheet to your instructor.

Study Guide

Safety

• Oxyacetylene safety

• SMAW safety

• Hand Tool Safety

SMAW and OAC Processes

• Power source specifics

o Polarity

o Current out put

• AWS electrode classification

• OAC

o Theory of cutting

o Flame types

o Safety

Welding Symbols and Blueprints

• Orthographic views

• Isometric views

• Welding symbol

o Weld symbols

o Reference line

o Tail

Math and Math conversions

� Adding and subtracting fractions

� Reading a tape measure

� Metric conversions

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WLD 253 Answer Sheet

Name: ________________________________ Date: ___________________

1.

11.

2.

12.

3.

13.

4.

14.

5.

15.

6.

16.

7.

17.

8.

18.

9.

19.

10.

20.

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Welding Procedure Specification

AWS D1.1 Job No.:

WPS Number:

Rev. Number Original

Date:

PQR Number: Prequalified

Title: Shielded Metal Arc—Groove with Carbon Steel Backing

Welding Process: Shielded Metal Arc Type: Manual Mode:

Prepared by: Date: Approved by: Date:

JOINT DESIGN Type: Single Groove B-L2a

Single or Double Weld: Single Backing : Yes

Backing Material: Carbon Steel

Root Opening-R: 1/4”

Land-L: 0-1/8” Radius (J-U): N/A

PREHEAT Preheat Temp. Min. 60°

Interpass Temp. Min: 60° F Max: 400°F

TECHNIQUE/ OTHER

� Stringer or � Weave Beads

� Multipass or � Single pass per side

� Single or � Multiple Electrodes

Contact Tube to Work Distance:

N/A Peening: None on root or cover

Initial Cleaning:

All areas to be welded shall be cleaned for

oil, grease, paint, etc., for at least two (2)

inches from the toes of the weld

Interpass Cleaning:

Remove all oxides and slag with a clean

wire brush and/or chipping hammer

Notes:

1. A stringer or slight weave may be used

as required to provide proper bead shape

and side wall wetting.

2. Initial and interpass cleaning shall be

accomplished by wire brushing, chipping,

and no grinding.

3. Welder shall accomplish a visual

inspection of previously deposited weld

metal, prior to depositing the next bead.

BASE METALS Metal Specification: A36

Type or Grade: Grade A

Group 1 Plate Thickness: 3/8”

Thickness Groove: 3/8” Fillet: All

Diameter (Pipe) 24” and up Wall 1/8” and u

FILLER METALS Classification: E6011

Specification No. AWS 5.1

SHIELDING Gas: N/A Composition: N/A

Flow Rate: N/A

Gas Cup Size: N/A

Electrode-Flux (Class): N/A

Flux: N/A

WLD 253 6/18/12

Matt Scott

36

POSITION

Position of Groove or Fillet: 1G, 2G, 3G, 4G, 1F,

2F, 3F, 4F

Vertical Progression: Up

4. Welding electrode shall be stored in

dry area and located in close proximity to

the work area.

5. Preheating shall be accomplished using

oxy-fuel torches.

6. Weld shall be allowed to cool slowly,

keeping air drafts to a minimum.

POSTWELD HEAT TREATMENT Temperature Range:

Time:

Pass or

Weld

Layer(s) Process

Filler Metals Current

Volts

Travel

Speed

(IPM)

Joint

Details

Class Dia.

Type

and

Polarity

Amps or

wire feed

speed

All SMAW E6011 1/8” DCEP 90-170A 19-27 2-4

WLD 253 6/18/12

Matt Scott

37

Final Grades - WLD 253 Name: _________________ Instructor: ___________________ Date: __________________

Welding Projects = 40%

Out of Out of Out of

Out of Out of Out of

Out of Out of Out of

Out of Out of Out of

Out of Out of Out of

Out of Out of Out of

A Total Project pts. ________ / Total pts. Possible _______ X 40 = _______ %

Written Work = 20%

Out of Out of Out of

Out of Out of Out of

Out of Out of Out of

B Total Project pts. ________ / Total pts. Possible _______ X 20 = _______ %

Safety = 15% Each day of attendance is worth 3 points earned. Any safety violation will result in 0 points for the

day.

Out of Out of Out of Out of Out of Out of

Out of Out of Out of Out of Out of Out of

Out of Out of Out of Out of Out of Out of

C Total pts. earned ________ / Total pts. Possible _______ X 15 = _______ %

Employability Skills = 15% The following attributes will be assessed - attendance, attitude, time management,

team work, interpersonal skills, etc.. Daily points (there are no excused absences, hence no points earned for days

missed ) 3 pts = present and working for the entire shift; 2 pts = late; 1 pt = late and left early; 0 pts = no show.

Out of Out of Out of Out of Out of Out of

Out of Out of Out of Out of Out of Out of

Out of Out of Out of Out of Out of Out of

D Total pts. earned ________ / Total pts. Possible _______ X 15 = _______ %

Final Exam 10%

Written Exam Out of

E Total Project pts. ________ / Total pts. Possible _______ X 10 = _______ %

Add Lines A + B + C + D + E. This will give you your Final Grade TOTAL % _________

FINAL GRADE _________