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WLD 254 SMAW Certification Practice 3/8" Mild Steel (E7018)
WLD 254
SMAW Certification Practice
3/8" Mild Steel (E7018)
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Index
Course Information 3
Visual Inspection Criteria
4
Math on Metal 5-9
Performance Qualification Work sheet
10-11
Craftsmanship Expectations for Welding
Projects
SMAW Information sheets
12
13-20
• Plate Fit-up
• Root Pass Inspection and Inter
Pass Cleaning
• Bend Test Procedures
Welding Projects
21-24
Final Exam Information
25-28
Assessment Breakdown for the Course
29
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
ANSI/AWS D1.1 Structural Welding Code, Performance Qualification
Reference List
Standard Welding Terms and Definitions, ANSI/AWS A3.0-94
Work Sheets
Performance Qualification
Welding Projects
3G Certification Preparation
4G Certification Preparation
Bend Test Procedures
Final Exam
Closed Book Exam Directions
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 based on final exam/project
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Visual Inspection Criteria
This section will familiarize the student with inspection criteria that will be applied to the
evaluation of their projects. PCC Welding Department utilizes the visual inspection
requirements set forth under the Welder Qualification Section in AWS D1.1 1996 or newer
code. The following criteria are gathered from this source.
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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Heat Input Problems
It is important to know your heat input into a plate when you are welding, as well as heat
limitations for different metals. Some metals are more heat-insensitive than others, and damage
caused by too much heat input might not be detectable for days.
The heat input (H) equation is
HEAT INPUT = voltage x current ÷÷÷÷ welding travel speed
or
{Remember that a fraction is just a
Heat Input = S
IxV division problem: top divided by bottom}
where voltage is measured in volts (V), current in amperes or amps (I),and travel speed (S) in
inches per second. It is often necessary to convert travel speed information given in inch/minute
format to inches per second before using in the heat input equation. The heat input answer is
usually given as a rate in joules/inch or kilojoules/inch. A joule is a unit of energy equivalent to
one watt of power radiated for one second.
Example: Given a travel speed of 8 in/min, a voltage of 120 volts and a current of 100 amps,
what is your heat input?
First, convert your speed from inches per minute to inches per second to conform to the
equation: Remember, seconds are smaller units of time, so you can travel fewer inches in a
second than in a minute. You will need to divide your inches per minute by 60:
8 in/min = min1
8 inches =
sec60
8 inches =
60
8 = 8 ÷÷÷÷ 60 or . . .
.13333… in/sec . . . use this or 8/60 as your speed -- “S” in the heat input equation:
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H = S
IxV =
60
8
100120 x or
1333333.
100120 x
= 90,000 J/in = 90 kJ/in “ninety-thousand joules . . .” “ninety-thousand joules . . .”
Note: the easiest way to do the above calculation is to:
multiply 120 by 100
then divide by 8/60 (entered using the fraction key)
and then push “=”
Usually, you measure your amperes, voltage and travel speed, and then you figure your heat
input to tell you whether you are overheating the metal.
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Heat Input Worksheet—WLD 254
Name: ____________________________________ Date: _______________________
Try these problems--- Show your work:
1. What is the heat input in kJ/in for a travel speed of 6 inches per minute, a voltage of 35,
and a current measuring 280 amps? Remember to convert your answer in joules to
kilojoules by dividing by 1000.
2. Calculate your heat input in kJ/in for a voltage of 120 V, a current of
100 amps, and a travel speed of 4 in/minute.
3. Calculate your heat input in kJ/in for a current of 300 A, a voltage of
30, and a travel speed of 3 in/min.
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4. If your voltage is 30 V and your current is 250 A, what kind of travel
speed would get you a heat input of 2.3 kJ/in?
5. What should your heat input be for a voltage of 40 V, a current of 310
amps, and a travel speed of 3.2 in/min? Remember to give it in kJ/in.
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Performance Qualification – WLD 254
Name: ___________________________ Date: _____________________
Directions
Reference the AWS D1.1 Structural 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 code or your text book to find an answer.
1. What are the dimensions for an optional test plate for limited thickness test in accordance
with AWS Horizontal Position?
2. What is the maximum thickness for a groove weld a welder is qualified to weld if s/he
has previously passed a 3/8" plate tests in accordance with AWS D1.1?
3. A welder passes a 3/8" plate (3G) test, what position(s) is s/he qualified to weld in?
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4. A welder originally passed a qualification test with the an E7018, is s/he qualified to
weld with an E6011?
5. A slag pocket that is 3/16" long is on the convex surface of a bend test. Is this acceptable
or reject able? Why?
6. What are the acceptance criteria for both visual and mechanical testing on a 3/8" groove
welding test?
7. A welder fails a vertical up test. Can s/he retake the test immediately? Why or why not?
8. How long is a welding certification good for?
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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 Section 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
Root Pass 100% fusion, free of slag and
porosity
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 (also known
as “Finger Clamps” or “Cowboy
Clamps”) 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.
Tack the plates at the ends only
Not on the backside.
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 not their
grinding skills.
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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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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 print below
for bend test lay out requirements. 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
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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.
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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E7018 Butt Joint- Single Vee (3G) Project #1 Welding Sequence
E7018-- Root Pass Single pass technique with slight weave to ensure the weld metal is fusing
into all three pieces of metal.
E7018—Fill Use the split bead technique with stringer beads ensuring even fill.
E7018—Finish Beads Use stringer bead technique keeping the electrode in the puddle at all
times.
______________________________________________________________________________
Bead Placement High Quality Cover Passes
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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E7018 Butt Joint- Single Vee (4G) Project #2
Welding Sequence
E7018-- Root Pass Single pass technique with slight weave to ensure the weld metal is fusing
into all three pieces.
E7018—Fill Use the split bead technique with stringer beads ensuring even fill.
E7018—Finish Beads Use stringer bead technique keeping the electrode in the puddle at all
times.
______________________________________________________________________________
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
The final exam is a closed book test. Consult your instructor to determine items that you may
need to review. Once you determine that you are ready for final written exam see your instructor.
Complete the exam and write all answers on the answer sheet. Once completed, return the exam
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 254 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,
no grinding allowed.
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: E7018
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
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POSITION
Position of Groove or Fillet: 1G, 2G, 3G, 4G, 1F,
2F, 3F, 4F
Vertical Progression: Up
4. Welding electrode shall be stored in
portable heated rod ovens, 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 E7018 1/8” DCEP 90-170A 19-27 2-5
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Final Grades - WLD 254 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 _________
