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BC WELDER TRAINING PROGRAM FOUNDATION AND APPRENTICESHIP LEVELS 1 AND 2 P4 (Line D): Shielded Metal Arc Welding I (SMAW I) Practical Competencies

Acknowledgements & Copyright Permission The Industry Training Authority of British Columbia would like to acknowledge the Welding Articulation Committee and Open School BC, as well as the following individuals and organizations for their contributions in updating the Welder Training modules: Version 1 Contributors (2010) Welding Articulation Committee (WAC) Members and Consultants The Working Group Jim Carson (Welding Articulation Committee Chair), University of the Fraser Valley (writer and senior reviewer) Peter Haigh (Welding Curriculum Review Committee Chair), Northwest Community College (writer and senior reviewer) Sheldon Frank, University of the Fraser Valley (writer and reviewer) Greg Burkett, Okanagan College (writer and reviewer) Randy Zimmerman (writer and reviewer) John H.P. Little (reviewer) Resource Training Organization (RTO) BC Council on Admissions and Transfer (BCCAT) The Queen s Printer In 2010, the Queen s Printer, through its Open School BC unit, provided project management and design expertise in updating the Welder Training Level C print materials. Open School BC Solvig Norman, Senior Project Manager Eleanor Liddy, Director/Advisor Dennis Evans, Production Technician (print layout, graphics & photographs) Christine Ramkeesoon, Graphics Media Coordinator Keith Learmonth, Editor Margaret Kernaghan, Graphic Artist Publishing Services Sherry Brown, Director of Publishing Services Intellectual Property Program Ilona Ugro, Copyright Officer, Ministry of Citizens Services, Province of British Columbia Copyright Permission The following suppliers have kindly provided copyright permission for selected product images: Acklands-Grainger Inc. The Crosby Group J. Walter Company Ltd. Lincoln Electric Company NDT Systems, Inc. Praxair, Inc. Thermadyne Canada (Victor Equipment) The Miller Electric Mfg. Co. ESAB Welding & Cutting Products Photo of welder walks the high steel at a construction site, Kenneth V. Pilon, copyright 2010. Used under license from Shutterstock.com

A special thank you to Lou Bonin and Jim Stratford at Camosun College (Welding department) for assisting us with additional photographs. An additional thank you to Richard Smith from England, for allowing us to use photographs of hydrogen bubbles. Version 2 Contributors (2017) The Welding Level C Modules were updated in 2017 to reflect the 2016 (Harmonized) Program Outline with Levels 1 and 2 referenced throughout the covers, titles, headers, tabs and tab pages. Welding Articulation Committee Mark Flynn (Welding Articulation Committee Chair), British Columbia Institute for Technology Al Sumal, Kwantlen Polytechnic University Jim Carson, University of the Fraser Valley Colin Makeiv, Selkirk College Open School BC Jennifer Riddel, Manager of Instructional Services Solvig Norman, Project Manager Sharon Barker, Production Technician

Foreword The Industry Training Authority (ITA) is pleased to release this minor update of learning resources to support the delivery of the 2016 BC Welder Program Foundation and Apprenticeship Levels 1 and 2. It was made possible by the dedicated efforts of the Welding Articulation Committee of BC (WAC). The WAC is a working group of welding instructors from institutions across the province and is one of the key stakeholder groups that support and strengthen industry training in BC. It was the driving force behind the update of the welding learning modules supplying the specialized expertise required to incorporate technological, procedural and industry-driven changes. The WAC plays an important role in the province s postsecondary public institutions as discipline specialists that share information and engage in discussions of curriculum matters, particularly those affecting student mobility. We are grateful to WAC for their contributions to the ongoing development of BC Welder Training Program Learning Resources (materials whose ownership and copyright are maintained by the Province of British Columbia through ITA). Disclaimer Industry Training Authority March 2017 The materials in these modules are for use by students and instructional staff and have been compiled from sources believed to be reliable and to represent best current opinions on these subjects. These manuals are intended to serve as a starting point for good practices and may not specify all minimum legal standards. No warranty, guarantee or representation is made by the British Columbia Welding Articulation Committee, the British Columbia Industry Training Authority or the Queen s Printer of British Columbia as to the accuracy or sufficiency of the information contained in these publications. These manuals are intended to provide basic guidelines for welding trade practices. Do not assume, therefore, that all necessary warnings and safety precautionary measures are contained in this module and that other or additional measures may not be required.

P4 (Line D): Shielded Metal Arc Welding I (SMAW I) Practical Competencies Table of Contents Practical Competency P4-11 (Line D-D6): Bead welds in the flat position on low-carbon steel plate 9 P4-11 Learning Task 1: Strike an arc on low-carbon steel plate............... 13 WPS P4-11-1A: Strike an arc using the scratch method................ 16 WPS P4-11-1B: Strike an arc using the tap method.................. 18 WPS P4-11-1C: Strike an arc with an E4918 (E7018) electrode using the scratch and tap methods................................... 20 P4-11 Learning Task 2: Bead welds in the flat position on low-carbon steel plate...... 21 WPS P4-11-2A: Stringer bead welds in the flat position................ 22 WPS P4-11-2B: Weave bead welds in the flat position................. 24 Practical Competency P4-12 (Line D-D6): Fillet welds on low-carbon steel plate 27 P4-12 Learning Task 1: Fillet welds in the flat (1F) position on lap, tee and corner joints on low-carbon steel plate........................ 31 WPS P4-12-1A: Single-pass fillet welds on lap joints in the 1F position......... 32 WPS P4-12-1B: Multi-pass fillet welds on tee joints in the 1F position......... 36 WPS P4-12-1C: Multi-pass fillet welds on corner joints in the 1F position....... 40 P4-12 Learning Task 2: Fillet welds in the horizontal (2F) position on lap, tee and corner joints on low-carbon steel plate........................ 43 WPS P4-12-2A: Multi-pass fillet welds on lap joints in the 2F position......... 44 WPS P4-12-2B: Multi-pass fillet welds on tee joints in the 2F position......... 46 WPS P4-12-2C: Multi-pass fillet welds on corner joints in the 2F position....... 50 P4-12 Learning Task 3: Fillet welds in the vertical (3F) uphill position on lap, tee and corner joints on low-carbon steel plate...................... 53 WPS P4-12-3A: Single-pass fillet welds on lap joints in the 3F uphill position...... 54 WPS P4-12-3B: Multi-pass fillet welds on tee joints in the 3F (up hill) position..... 58 WPS P4-12-3C: Multi-pass fillet welds on corner joints in the 3F uphill position.... 60 P4-12 Learning Task 4: Fillet welds in the overhead (4F) position on lap, tee and corner joints on low-carbon steel plate...................... 63 WPS P4-12-4A: Multi-pass fillet welds on lap joints in the 4F position......... 64 WPS P4-12-4B: Multi-pass fillet welds on tee joints in the 4F position......... 66 WPS P4-12-4C: Multi-pass fillet welds on corner joints in the 4F position....... 68 P4-12 Learning Task 5: Weld a pipe or structural section to a plate in the horizontal (2F) position.................................. 71 WPS P4-12-5: Multi-pass fillet weld joining the end of a structural section to a plate.. 72 P4-12 Learning Task 6: Weld pipe to plate in the 5F position............... 73 WPS P4-12-6: Multi-pass fillet weld between a pipe and a vertical plate........ 74 6 FOUNDATION AND APPRENTICESHIP LEVELS 1 AND 2

Practical Competency P4-13 (Line D-D6): Fillet welds on low-carbon steel sheet 77 P4-13 Learning Task 1: Fillet welds in the horizontal (2F) position on lap and tee joints on low-carbon steel sheet.......................... 81 WPS P4-13-1A: Single-pass fillet welds on lap joints in the 2F position......... 82 WPS P4-13-1B: Single-pass fillet welds on tee joints in the 2F position......... 84 P4-13 Learning Task 2: Fillet welds in the vertical (3F) position on laps and tee joints on low-carbon steel sheet................................. 87 WPS P4-13-2A: Single-pass fillet welds on lap joints in the 3F downhill position.... 88 WPS P4-13-2B: Single-pass fillet welds on tee joints in the 3F downhill position.... 90 Practical Competency P4-14: (Line D-D7) Hardface in the flat position on low-carbon steel plate 93 P4-14 Learning Task 1: Build up and hardface low-carbon steel plate in the flat position.. 97 WPS P4-14-1A: Build up low-carbon steel plate in the flat position........... 98 WPS P4-14-1B: Hardface a waffle pattern on low-carbon steel plate in the flat position..................................... 100 WPS P4-14-1C: Hardface a button pattern on low-carbon steel plate in the flat position..................................... 102 Practical Competency P4-15 (Line D-D8): Groove welds on grey cast iron in the flat (1G) position 105 P4-15 Learning Task 1: Groove welds on grey cast iron in the flat (1G) position..... 109 WPS P4-15-1: Single vee butt joint on grey cast iron in the 1G position....... 110 Practical Competency P4-16 (Line D-D3 and D9): Stainless steel welds on low-carbon steel plate 113 P4-16 Learning Task 1: Multi-pass fillet welds on tee joints in the horizontal (2F) position using stainless steel electrodes................. 117 WPS P4-16-1: Multi-pass fillet welds on tee joints in the 2F position......... 118 Practical Competency P4-17 (Line D-D6): Groove welds on low-carbon steel plate 121 P4-17 Learning Task 1: Functions of a welding procedure specification (WPS)...... 125 P4-17 Learning Task 2: Single vee butt joint with open root in the 1G position on low-carbon steel plate................................ 127 WPS P4-17-2A: Prepare and weld single vee butt joints............... 128 WPS P4-17-2B: Prepare face- and root-bend test coupons for a single vee butt joint................................ 130 P4-17 Learning Task 3: Single bevel butt joint with backing in the 1GF position on low-carbon steel plate................................ 133 WPS P4-17-3A: Prepare and weld single bevel butt joints with backing....... 134 WPS P4-17-3B: Prepare face- and root-bend test coupons for a single bevel butt joint............................. 136 P4-17 Learning Task 4: Single bevel butt joint with backing in the 2GF position on low-carbon steel plate................................ 139 WPS P4-17-4A: Prepare and weld single bevel butt joints with backing....... 140 BC WELDER TRAINING PROGRAM 7

WPS P4-17-4B: Prepare face- and root-bend test coupons for a single bevel butt joint............................... 142 P4-17 Learning Task 5: Single bevel butt joint with backing in the 3GF uphill position on low-carbon steel plate................................ 145 WPS P4-17-5A: Prepare and weld single bevel butt joints with backing....... 146 WPS P4-17-5B: Prepare face- and root-bend test coupons for a single bevel butt joint............................... 148 P4-17 Learning Task 6: Single bevel butt joint with backing in the 4GF position on low-carbon steel plate................................ 151 WPS P4-17-6A: Prepare and weld single bevel butt joints with backing....... 152 WPS P4-17-6B: Prepare face- and root-bend test coupons for a single bevel butt joint............................... 154 8 FOUNDATION AND APPRENTICESHIP LEVELS 1 AND 2

Practical Competency P4-11 (Line D-D6): Bead welds in the flat position on low-carbon steel plate P4-11 (F & L1)

Practical Competency P4-11 (Line D-D6) Outcomes You have learned the basic information about shielded metal arc welding (SMAW) and its applications. You will now have the opportunity to actually use the SMAW process. When you have completed the Learning Tasks in Practical Competency P4-11, you will be able to: strike an arc using the tap and scratch methods weld stringer beads in the flat position weld weave beads in the flat position Evaluation You will be required to do the following: strike an arc using the tap and scratch methods weld stringer beads in the flat position weld weave beads in the flat position Your instructor will evaluate your ability at each step. Materials Each Learning Task procedure identifies the materials you will need to complete the assigned procedure. Your instructor will arrange for these materials to be available to you. WARNING! If a Practical Competency procedure requires that you use a tool or piece of equipment that you have not previously operated or you feel unsure about the operation of any tools or equipment ask your instructor to demonstrate the correct procedures for the tool or piece of equipment before you use it. Use of materials Welding is a very expensive trade. The cost of steel, filler metal and other consumables can rise or fall, depending on the marketplace. The only area in which there can be significant potential savings is in how we use steel. Steel is the largest single consumable cost. This is true in both training and industry. Training institutions often have to buy scrap material to practise on. Therefore, steel used for practise might not be the exact size or thickness laid out in the Practical Competencies. This will not affect your learning. In fact, it might even better reflect the reality of the real welding world, where it is common practise to substitute material sizes. BC WELDER TRAINING PROGRAM 11

Practical Competency P4-11 (Line D-D6) When cutting new steel or steel crops, always strive for maximum use and minimum waste. Cut pieces from one end of plate so as to leave the largest possible area untouched for later use. Assemble lap joints and tee joints in a way that will reduce waste and maximize the size of off-cuts after welding. General procedures for all welding Practical Competencies 1. Arrange with your instructor for a demonstration of all procedures and for the tools and equipment you will need. 2. Follow all safety precautions, wear all personal protective clothing and use all personal protective equipment. Review P1-2: Use Safe Work Practises. 3. Clean the base metal, if necessary. Remove any rust, mill scale or paint. 4. You will be required to repeat procedures until you receive an acceptable evaluation from your instructor. 12 FOUNDATION AND APPRENTICESHIP LEVELS 1 AND 2

Practical Competency P4-11 (Line D-D6) P4-11 Learning Task 1: Strike an arc on low-carbon steel plate To complete this Learning Task, you must perform the following procedures: Procedure 1A: Strike an arc using the scratch method Procedure 1B: Strike an arc using the tap method Procedure 1C: Strike an arc with an E4918 (E7018) electrode using the scratch and tap methods To strike an arc, you simply touch the electrode to the base metal. You must then immediately lift the electrode. The arc forms as soon as the electrode is lifted from the base metal. If you allow the electrode to remain in contact with the base metal, the two will fuse. If you lift the electrode too far from the base metal, the arc will go out. In this Learning Task, you will practise using two different electrodes to strike an arc using both the scratch and the tap methods. With the scratch method, you scratch the electrode across the surface of the base metal, similar to striking a large match. With the tap method, you tap the electrode straight down on the base metal and lift it straight back up. Materials Base metal The tap method is the main method used to strike an arc. It reduces the chance of arc strikes on the surrounding material. Low-carbon steel plate from shop scraps about 6 mm ( 1 4") thick Filler metal E4310/E4311 (E6010/E6011), 4.0 mm ( 5 32") diameter E4918 (E7018), 4.0 mm ( 5 32") diameter Welding Procedure Specification (WPS) Polarity DCEP DCEP A welding procedure specification (WPS) data sheet is a standard form that is used in the welding industry to lay out and describe a welding procedure. By having the WPS data sheet, the design staff and the Welder know exactly how the weld is to be done. They can rely on this approved procedure to give them a good-quality weld. BC WELDER TRAINING PROGRAM 13

Practical Competency P4-11 (Line D-D6) Some welding shops are certified by governing bodies that set standards in weld quality. This is done so that engineers and customers know that the Welders and their welds will meet a set standard of quality. Many shops are certified under the Canadian Welding Bureau (CWB) or the American Society of Mechanical Engineers (ASME). There are also shops certified for building ships, aircraft, railroad equipment and petrochemical equipment. Welding and fabrication shops that are CWB certified often construct components of large structures that have to be built to design code. ASMEcertified shops often build pressure vessels, piping systems and boilers. In both cases, faulty welds could have lethal results. Having a system of weld procedures that have been proven to meet code ensures that they will produce a safe product for the customer and end user. At first your Practical Competencies will provide you with a step-by-step procedure to follow. Gradually, you will encounter simplified versions of a Welding Procedure Specification (WPS) data sheet in your Practical Competencies. This will help you become familiar with the format. Eventually you will be able to read a one- or two-page WPS data sheet and understand what has to be done to make a quality weld. A WPS gives you all the information you require in an abbreviated form. The following is a sample WPS with descriptions of the information it contains. 14 FOUNDATION AND APPRENTICESHIP LEVELS 1 AND 2

Practical Competency P4-11 (Line D-D6) Welding Procedure Specification (WPS): This identifies the procedure by number and/or name, etc. Position: This gives the position of the weld, such as flat, horizontal, vertical up or overhead. Depending on joint design, the position can be expressed as 1F, 1G, 2F, 2G, etc. Joint Design and Tolerance: A diagram will be placed here illustrating the joint design. It might include welding symbols to identify the size and location of the weld. Process: This area gives the type of welding process to be used, such as SMAW, GMAW or SAW. Suggested Sequence: A diagram illustrating more information is often placed here to show details of the weld sequence if necessary. Base Metal: The base metal type, grade, specification and thickness are identified here. Often in industry the exact alloy can be very important. Filler Metal: The electrode or filler metal specification is listed here. Filler metal can be identified by its classification number (e.g. E4310, E4918, etc.) or by its group number (e.g. F1, F2, F3, etc.). Welding : Special instructions regarding size, placement of tack welds, motions or length of arc, wire feed rates, welding speed, etc., are listed here. Diameter of Electrode: Normally identifies a range of electrode diameters that can be used. Shielding: The type of shielding to be used if required. It may be a gas or loose flux. Electrical Characteristics: This could include polarity, amperage, voltage, etc. Directions: Additional information, step-by-step instructions, diagrams or anything else to make sure the Welder understands and is able to produce the required weld. Information could include: 1. preheating and post-heating temperatures and procedures 2. pre- and post-weld and weldment cleaning processes and procedures 3. methods of joint preparation BC WELDER TRAINING PROGRAM 15

Practical Competency P4-11 (Line D-D6) WPS P4-11-1A: Strike an arc using the scratch method Directions 1. Turn on the welding power source. 2. Set the welding power source by selecting the correct polarity and current settings for the E4310/E4311 (E6010/E6011) electrode. 3. Attach the ground clamp to your workpiece. 4. Insert the electrode into the electrode holder. 5. Hold the electrode about 25 mm (1 in.) above the base metal. It should be perpendicular to the base metal and inclined 10 to 20 in the direction of travel. 6. Lower your welding helmet and strike an arc by quickly and gently dragging the electrode across the base metal, using a wrist movement only (Figure 1). If you strike the arc correctly, a burst of light (an arc) will occur. Scratch electrode across base metal with wrist movement only Figure 1 Scratch method 16 FOUNDATION AND APPRENTICESHIP LEVELS 1 AND 2

Practical Competency P4-11 (Line D-D6) 7. Lift the electrode about 6 mm ( 1 4 in.). Hold this distance for a second or two. Then lower the electrode until it is 3 mm ( 1 8 in.) away from the base metal. The purpose of holding a long arc for that second or two is to allow the tip to heat up, making the arc more stable. Maintain the arc for three or four seconds. Then pull the electrode away from the steel plate until the arc is broken. 8. Practise using the scratch method to strike an arc until you can do it smoothly every time. Keep your weld deposits on one-half of one side of the steel plate. Use your electrode until it is a stub less than 50 mm (2 in.) long. Discard the stub in the metal container designated for stubs. 9. Always use pliers to position the plate after it has been exposed to the arc. It will get hot! If you pick up hot metal with your gloves, you will burn the fingertips and harden the leather. The gloves will no longer insulate your fingers from the heat. 10. When you feel you can strike and maintain an arc smoothly, ask your instructor to evaluate your technique. BC WELDER TRAINING PROGRAM 17

Practical Competency P4-11 (Line D-D6) WPS P4-11-1B: Strike an arc using the tap method Directions 1. Turn on the welding power source. 2. Set the welding power source by selecting the correct polarity and current settings for the E4310/E4311 (E6010/E6011) electrode. 3. Attach the ground clamp to your workpiece. 4. Insert the electrode into the electrode holder. 5. Hold the electrode about 25 mm (1 in.) (Figure 2A) above the base metal. It should be perpendicular to the base metal and inclined 10 to 20 in the direction of travel. 6. Lower your welding helmet and strike an arc by moving the electrode straight down until it touches the base metal (Figure 2B). When the burst of light occurs, bring the electrode up to 6 mm ( 1 4 in.) (Figure 2C) from the base metal. Hold this length for a second or two, then lower the electrode until it is 3 mm ( 1 8 in.) (Figure 2D) away from the plate. Maintain the arc for three or four seconds, then break the arc by pulling the electrode away from the base metal. 25 mm (1") touch base metal A. Start position B. Touch base metal 6 mm (¼") 3 mm (1 8") C. Raise electrode 6 mm (¼") D. Lower to 3 mm (1 8") to start welding Figure 2 Tap method 18 FOUNDATION AND APPRENTICESHIP LEVELS 1 AND 2

Practical Competency P4-11 (Line D-D6) 7. Practise using the tap method to strike an arc until you can do it smoothly every time. Keep your weld deposits on the other half of the side of the base metal you used for Procedure 1A. Use your electrode until it is a stub 50 mm (2 in.) long. Discard the stub in the metal container designated for stubs. 8. Always use pliers to position the plate after it has been exposed to the arc. It will get hot! If you pick up hot metal with your gloves, you will burn the fingertips and harden the leather. The gloves will no longer insulate your fingers from the heat. 9. When you can strike and maintain an arc smoothly, ask your instructor to evaluate your technique. BC WELDER TRAINING PROGRAM 19

Practical Competency P4-11 (Line D-D6) WPS P4-11-1C: Strike an arc with an E4918 (E7018) electrode using the scratch and tap methods Directions 1. Set the welding power source by selecting the correct polarity and current settings for the E4918 (E7018) electrode. 2. Follow the steps in Procedure 1A for the scratch method using the E4918 (E7018) electrode. Use the reverse side of your plate. Use your electrode until it is a stub less than 50 mm (2 in.) long. Discard the stub in a metal container designated for stubs. 3. Clean up your weldment by removing the slag and spatter with a chipping hammer and wire brush. 4. Follow the steps in Procedure 1B for the tap method using the E4918 (E7018) electrode. 5. When you can strike and maintain each arc smoothly, ask your instructor to evaluate your technique. 20 FOUNDATION AND APPRENTICESHIP LEVELS 1 AND 2

Practical Competency P4-11 (Line D-D6) P4-11 Learning Task 2: Bead welds in the flat position on lowcarbon steel plate To complete this Learning Task, you must perform the following procedures: Procedure 2A: Weld stringer beads in the flat position Procedure 2B: Weld weave beads in the flat position BC WELDER TRAINING PROGRAM 21

Practical Competency P4-11 (Line D-D6) WPS P4-11-2A: Stringer bead welds in the flat position Materials Base metal Low-carbon steel plate from shop scrap about 13 mm ( 1 2") thick Filler metal Polarity E4310/E4311 (E6010/E6011), 4 mm ( 5 32") diameter DCEP E4918 (E7018), 4 mm ( 5 32") diameter DCEP E4924 (E7024), 4 mm ( 5 32") diameter DCEN Welding symbol SMAW Directions 1. Use your combination square and soapstone to lay out lines lengthwise 13 mm ( 1 2 in.) apart on both sides of your base metal (Figure 3). These lines will act as a guide so your beads are straight and evenly spaced. 13 mm ( 1 2") Soapstone lines Figure 3 Markings on the plate 2. Select the correct polarity and current settings for the E4310/E4311 (E6010/E6011) electrode. Attach the ground clamp to your workpiece. Insert the electrode in the electrode holder. 22 FOUNDATION AND APPRENTICESHIP LEVELS 1 AND 2

Practical Competency P4-11 (Line D-D6) 3. Position your workpiece so that you will be welding in the flat position. 4. Run a stringer bead along each of the layout lines. The bead should be about 6 mm ( 1 4 in.) wide (Figure 4). Adjust your rate of travel and electrode angle to achieve the correct size of bead. Be sure the weld is straight and consistent in width. 6 mm ( 1 4") Figure 4 Stringer beads on plate Generally, a stringer weld bead will be up to two times the outside diameter of the welding electrode, including flux. Heavier flux coatings produce wider beads for the same wire diameter. Weave beads should be about three to a maximum of four times the outside diameter of the electrode. 5. Clean up your weldment by removing the slag and spatter with a chipping hammer and wire brush. Make sure you wear safety glasses and a full face shield or your welding helmet with the filter lens flipped up when cleaning your weld. With the soapstone, mark the plate with the type of electrode used. Always use pliers to pick up the plate. 6. Show your work to your instructor. He/she will evaluate your work for: correct bead width reasonably smooth straight beads absence of arc strikes overall appearance 7. Repeat the steps in this procedure using the E4918 (E7018) and E4924 (E7024) electrodes. BC WELDER TRAINING PROGRAM 23

Practical Competency P4-11 (Line D-D6) WPS P4-11-2B: Weave bead welds in the flat position Materials Base metal Low-carbon steel plate from shop scrap about 13 mm ( 1 2") thick Filler metal Polarity E4310/E4311 (E6010/E6011), 4 mm ( 5 32") diameter DCEP E4918 (E7018), 4 mm ( 5 32") diameter DCEP E4924 (E7024), 4 mm ( 5 32") diameter DCEN Welding symbol SMAW Directions 1. Locate the plate that has the E4310/E4311 (E6010/E6011) stringer beads on it from the previous exercise. 2. Select the correct polarity and current settings for the E4310/E4311 (E6010/E6011) electrode. Attach the ground clamp to your workpiece. Insert the electrode in the electrode holder. 3. Position your workpiece so that you will be welding in the flat position. 4. Using a weave (zigzag) pattern, run a bead between two of the singlepass stringer beads, going from crown to crown (Figure 5). 6 mm ( 1 4") Stringer bead Weave bead Figure 5 Weave bead 24 FOUNDATION AND APPRENTICESHIP LEVELS 1 AND 2

Practical Competency P4-11 (Line D-D6) 5. Continue welding beads using the weave method until you fill this side of the plate. 6. Clean up your weldment by removing the slag and spatter. Make sure you wear safety glasses and a full face shield or your welding helmet with the filter lens flipped up when cleaning your weld. With the soapstone, mark the plate with the type of electrode used. Always use pliers to handle the hot plate. 7. Show your work to your instructor. He/she will evaluate your beads for: correct bead width reasonably smooth beads crown-to-crown bead placement absence of arc strikes overall appearance 8. Repeat the steps in this procedure using the E4918 (E7018) and E4924 (E7024) electrodes. BC WELDER TRAINING PROGRAM 25

Practical Competency P4-11 (Line D-D6) 26 FOUNDATION AND APPRENTICESHIP LEVELS 1 AND 2

Practical Competency P4-12 (Line D-D6): Fillet welds on low-carbon steel plate The following table shows you where information about Levels 1 and 2 content are covered from the new Harmonized Program Outline (2016). P4-12 (F, L1 & L2) P4-12 LT1 Pages 29 40 Level 1 (1F) P4-12 LT2 Pages 41 50 Level 1 (2F) P4-12 LT3 Pages 51 59 Level 1 (3F) P4-12 LT4 Pages 61 67 Level 1 (4F) P4-12 LT5 Pages 69 70 Level 1 (2F Structrual Shape) Level 2 (2F Pipe to Pipe) P4-12 LT6 Pages 71 73 Level 2 (5F)

Practical Competency P4-12 (Line D-D6) Outcomes In this Practical Competency, you will learn to make SMAW fillet welds on low-carbon steel plates. You will practise welding in four positions on lap, tee and corner joints. You will also practise welding structural sections and pipe on plate. When you have completed the procedures in Practical Competency P4-12, you will be able to make SMAW fillet welds using a variety of electrodes in the: 1F position on lap, tee and corner joints 2F position on lap, tee and corner joints 3F uphill position on lap, tee and corner joints 4F position on lap, tee and corner joints 2F position with structural sections on plate 5F uphill position with pipe on plate Evaluation You will be required to do the following: SMAW fillet welds on low-carbon steel plate in a variety of positions Your instructor will evaluate your ability at each step. Materials Each Learning Task identifies the materials and tools you will need to complete the assigned procedure. Your instructor will arrange for these tools and materials to be available to you. WARNING! If a Practical Competency Learning Task requires that you use a tool or piece of equipment that you have not previously operated or you feel unsure about the operation of any tools or equipment ask your instructor to demonstrate the correct procedures for the tool or piece of equipment before you use it. Use of materials Welding is a very expensive trade. The cost of steel, filler metal and other consumables can rise or fall, depending on the marketplace. The only area in which there can be significant potential savings is in how we use steel. Steel is the largest single consumable cost. This is true in both training and industry. Training institutions often have to buy scrap material to practise on. Therefore, steel used for practise might not be the exact size or thickness laid out in the Practical Competencies. This will not affect your learning. In fact, it might even better reflect the reality of the real welding world, where it is common practise to substitute material sizes. BC WELDER TRAINING PROGRAM 29

Practical Competency P4-12 (Line D-D6) When cutting new steel or steel crops, always strive for maximum use and minimum waste. Cut pieces from one end of plate so as to leave the largest possible area untouched for later use. Assemble lap joints and tee joints in a way that will reduce waste and maximize the size of off-cuts after welding. General procedures for all welding Practical Competencies 1. Arrange with your instructor for a demonstration of all procedures and for the equipment you will need. 2. Follow all safety precautions, wear all personal protective clothing and use all personal protective equipment. Review P1-2: Use Safe Work Practises. 3. Clean the base metal, if necessary. Remove any rust, mill scale or paint. 4. You will be required to repeat procedures until you receive an acceptable evaluation from your instructor. 30 FOUNDATION AND APPRENTICESHIP LEVELS 1 AND 2

Practical Competency P4-12 (Line D-D6) P4-12 Learning Task 1: Fillet welds in the flat (1F) position on lap, tee and corner joints on low-carbon steel plate To complete this Learning Task, you must perform the following welding procedures: Procedure 1A: Single-pass fillet welds on lap joints in the 1F position Procedure 1B: Multi-pass fillet welds on tee joints in the 1F position Procedure 1C: Multi-pass fillet welds on corner joints in the 1F position BC WELDER TRAINING PROGRAM 31

Practical Competency P4-12 (Line D-D6) WPS P4-12-1A: Single-pass fillet welds on lap joints in the 1F position Materials Base metal Two pieces of low-carbon steel plate 10 mm or 13 mm ( 3 8" or 1 2") thick by 200 mm (8") wide Filler metal E4310/E4311 (E6010/E6011), 4 mm ( 5 32") diameter E4918 (E7018), 4 mm ( 5 32") diameter E4924 (E7024), 4 mm ( 5 32") diameter Welding symbol Polarity DCEP DCEP DCEN SMAW Directions 1. Position your two plates to make a lap joint (Figure 6). Overlap the plates no more than one thickness. Make sure the plates are tight together. Align the ends of the joint so the plates are flush with each other. t t t = thickness Figure 6 Lap joint plate alignment 2. Select the correct polarity and current setting for the E4310/E4311 (E6010/E6011) electrode. Attach the ground clamp to your workpiece. Insert the electrode in the electrode holder. 32 FOUNDATION AND APPRENTICESHIP LEVELS 1 AND 2

Practical Competency P4-12 (Line D-D6) 3. Make four tack welds 19 mm ( 3 4 in.) long, one at each end of the joint (Figure 7) and another two on the opposite side of the joint. Show your tack welds to your instructor before proceeding with the weld. Tack welds 19 mm (¾") t Tack welds Figure 7 Lap joint tack welds 4. When your instructor has approved your tack welds, place the joint at a 45 angle to achieve the true 1F position (Figure 8). 45º Figure 8 Lap joint in the 1F position BC WELDER TRAINING PROGRAM 33

Practical Competency P4-12 (Line D-D6) 5. Weld along the joint (Figure 9). Watch for excessive buildup or undercut. Adjust your rate of travel or electrode angle as necessary. Be sure the legs of the fillet weld are equal in length. 45º Figure 9 Completed fillet weld on a lap joint 6. Clean up your weldment by removing the slag and spatter with a chipping hammer and wire brush. 7. Show your work to your instructor. He/she will evaluate it for: correct alignment good penetration good fusion absence of porosity absence of undercut overall appearance absence of arc strikes reasonable smoothness absence of irregularities legs of equal length slightly convex profile 8. Repeat the procedure using the E4918 (E7018) and E4924 (E7024) electrodes. 34 FOUNDATION AND APPRENTICESHIP LEVELS 1 AND 2

Practical Competency P4-12 (Line D-D6) BC WELDER TRAINING PROGRAM 35

Practical Competency P4-12 (Line D-D6) WPS P4-12-1B: Multi-pass fillet welds on tee joints in the 1F position Materials Base metal Two pieces of low-carbon steel plate 10 mm or 13 mm ( 3 8" or 1 2") thick by 200 mm (8") wide Filler metal E4310/E4311 (E6010/E6011), 4 mm ( 5 32") diameter E4918 (E7018), 4 mm ( 5 32") diameter E4924 (E7024), 4 mm ( 5 32") diameter Welding symbol Polarity DCEP DCEP DCEN SMAW Directions 1. Position your two plates to make a tee joint. Set the vertical piece two thicknesses in from the edge of the bottom plate. Make sure that the bottom plate lies flat on the work surface and the vertical plate forms the tee at 90 to the bottom plate (Figure 10). Align the ends of the joint so the plates are flush with each other. 90º Figure 10 Tee joint plate alignment 36 FOUNDATION AND APPRENTICESHIP LEVELS 1 AND 2

Practical Competency P4-12 (Line D-D6) 2. Select the correct polarity and current setting for the E4310/E4311 (E6010/ E6011) electrode. Attach the ground clamp to your workpiece. Insert the electrode in the electrode holder. Tack weld the joint (Figure 11). 90º Tack welds Figure 11 Tee joint tack welds 3. Place the tee joint at a 45 angle to achieve the true 1F position (Figure 12). Tack welds 45º Figure 12 Tee joint in the 1F position BC WELDER TRAINING PROGRAM 37

Practical Competency P4-12 (Line D-D6) 4. Weld the tee joint in the sequence shown (Figure 13). Watch for excessive buildup or undercut. Adjust your rate of travel and electrode angle as necessary. Be sure the legs of the fillet weld are equal in length. 6 4 2 1 3 5 45º Figure 13 Completed multi-pass weld on a tee joint 5. Clean up your weldment by removing the slag and spatter with a chipping hammer and wire brush. 6. Show your work to your instructor. He/she will evaluate it for: correct alignment good penetration good fusion absence of porosity absence of undercut overall appearance absence of arc strikes reasonable smoothness absence of irregularities legs of equal length slightly convex profile 7. Repeat the procedure using the E4918 (E7018) and E4924 (E7024) electrodes. 38 FOUNDATION AND APPRENTICESHIP LEVELS 1 AND 2

Practical Competency P4-12 (Line D-D6) BC WELDER TRAINING PROGRAM 39

Practical Competency P4-12 (Line D-D6) WPS P4-12-1C: Multi-pass fillet welds on corner joints in the 1F position Materials Base metal Two pieces of low-carbon steel plate 10 mm or 13 mm ( 3 8" or 1 2") thick by 200 mm (8") wide Filler metal E4310/E4311 (E6010/E6011), 4 mm ( 5 32") diameter E4918 (E7018), 4 mm ( 5 32") diameter E4924 (E7024), 4 mm ( 5 32") diameter Welding symbol Polarity DCEP DCEP DCEN SMAW Directions 1. Position your two plates at 90 to each other for an open corner joint (Figure 14). Align the ends of the joint so the plates are flush with each other. 90º Figure 14 Open corner joint plate alignment 40 FOUNDATION AND APPRENTICESHIP LEVELS 1 AND 2

Practical Competency P4-12 (Line D-D6) 2. Select the correct polarity and current setting for the E4310/E4311 (E6010/E6011) electrode. Attach the ground clamp to your workpiece. Insert the electrode in the electrode holder. 3. Make two tack welds 19 mm ( 3 4 in.) long, one at each end of the joint (Figure 15). Tack welds 19 mm (¾") Figure 15 Corner joint tack welds 4. Place the corner joint in the true flat (1F) position (Figure 16). 5. Weld the joint (Figure 16). Take care to avoid excessive buildup by adjusting your rate of travel and electrode angle as necessary. Be sure the legs of the fillet weld are equal in length. 1 2 3 Figure 16 Completed multi-pass fillet weld on an open corner joint BC WELDER TRAINING PROGRAM 41

Practical Competency P4-12 (Line D-D6) 6. Clean up your weldment by removing the slag and spatter with a chipping hammer and wire brush. 7. Show your work to your instructor. He/she will evaluate it for: correct alignment good penetration good fusion absence of porosity absence of undercut overall appearance absence of arc strikes reasonable smoothness absence of irregularities legs of equal length slightly convex profile 8. Repeat the procedure using the E4918 (E7018) and E4924 (E7024) electrodes. 42 FOUNDATION AND APPRENTICESHIP LEVELS 1 AND 2

Practical Competency P4-12 (Line D-D6) P4-12 Learning Task 2: Fillet welds in the horizontal (2F) position on lap, tee and corner joints on low-carbon steel plate To complete this Learning Task, you must perform the following welding procedures: Procedure 2A: Multi-pass fillet welds on lap joints in the 2F position Procedure 2B: Multi-pass fillet welds on tee joints in the 2F position Procedure 2C: Multi-pass fillet welds on corner joints in the 2F position BC WELDER TRAINING PROGRAM 43

Practical Competency P4-12 (Line D-D6) WPS P4-12-2A: Multi-pass fillet welds on lap joints in the 2F position Materials Base metal Two pieces of low-carbon steel plate 10 mm or 13 mm ( 3 8" or 1 2") thick by 200 mm (8") wide Filler metal E4310/E4311 (E6010/E6011), 4 mm ( 5 32") diameter E4918 (E7018), 4 mm ( 5 32") diameter E4924 (E7024), 4 mm ( 5 32") diameter Welding symbol Polarity DCEP DCEP DCEN SMAW Directions 1. Position your two plates to make a lap joint (Figure 17). Overlap the plates no more than one thickness. Make sure the plates are tight together. Align the ends of the joint so the plates are flush with each other. t t t = thickness Figure 17 Lap joint plate alignment 2. Select the correct polarity and current settings for the E4310/E4311 (E6010/E6011) electrode. Secure the ground clamp to your workpiece. Insert the electrode in the electrode holder. 3. Make four tack welds 19 mm ( 3 4 in.) long, one at each end of the joint (Figure 18) and another two on the opposite side of the joint. 44 FOUNDATION AND APPRENTICESHIP LEVELS 1 AND 2

Practical Competency P4-12 (Line D-D6) Tack welds 19 mm (¾") t Tack welds Figure 18 Lap joint tack welds 4. Place the lap joint in the 2F position (Figure 19). 5. Weld along the joint in the sequence shown (Figure 19). Watch for excessive buildup or undercut. Adjust your rate of travel and electrode angle as necessary. Be sure the legs of the fillet weld are equal in length. 3 2 1 Figure 19 Completed fillet weld on a lap joint in the 2F position 6. Clean up your weldment by removing the slag and spatter with a chipping hammer and wire brush. 7. Show your work to your instructor. He/she will evaluate it for: correct alignment good penetration good fusion absence of porosity absence of undercut overall appearance absence of arc strikes reasonable smoothness absence of irregularities legs of equal length slightly convex profile 8. Repeat the procedure using the E4918 (E7018) and E4924 (E7024) electrodes. BC WELDER TRAINING PROGRAM 45

Practical Competency P4-12 (Line D-D6) WPS P4-12-2B: Multi-pass fillet welds on tee joints in the 2F position Materials Base metal Two pieces of low-carbon steel plate 10 mm or 13 mm ( 3 8" or 1 2") thick by 200 mm (8") wide Filler metal E4310/E4311 (E6010/E6011), 4 mm ( 5 32") diameter E4918 (E7018), 4 mm ( 5 32") diameter E4924 (E7024), 4 mm ( 5 32") diameter Welding symbol Polarity DCEP DCEP DCEN SMAW Directions 1. Position your two plates to make a tee joint. Set the vertical piece two thicknesses in from the edge of the bottom plate. Make sure that the bottom plate lies flat on the work surface and the vertical plate forms the tee at 90 to the bottom plate (Figure 20). Align the ends of the joint so the plates are flush with each other. 90º Figure 20 Tee joint plate alignment 46 FOUNDATION AND APPRENTICESHIP LEVELS 1 AND 2

Practical Competency P4-12 (Line D-D6) 2. Select the correct polarity and current setting for the E4310/E4311 (E6010/E6011) electrode. Attach the ground clamp to your workpiece. Insert the electrode in the electrode holder. 3. Make four tack welds 19 mm ( 3 4 in.) long, one at each end of the joint and another two on the opposite side of the joint (Figure 21). 90º Tack welds Figure 21 Tee joint tack welds 4. Place the tee joint in the 2F position (Figure 22). 5. Weld the tee joint (Figure 22). Watch for excessive buildup or undercut. Adjust your rate of travel and electrode angle as necessary. Be sure the legs of the fillet weld are equal in length. 6 2 1 5 4 3 Figure 22 Completed fillet weld on a tee joint in the 2F position BC WELDER TRAINING PROGRAM 47

Practical Competency P4-12 (Line D-D6) BC WELDER TRAINING PROGRAM 49

Practical Competency P4-12 (Line D-D6) WPS P4-12-2C: Multi-pass fillet welds on corner joints in the 2F position Materials Base metal Two pieces of low-carbon steel plate 10 mm or 13 mm ( 3 8" or 1 2") thick by 200 mm (8") wide Filler metal E4310/E4311 (E6010/E6011), 4 mm ( 5 32") diameter E4918 (E7018), 4 mm ( 5 32") diameter E4924 (E7024), 4 mm ( 5 32") diameter Welding symbol Polarity DCEP DCEP DCEN SMAW Directions 1. Position your two plates at 90 to each other for an open corner joint (Figure 23). Align the ends of the joint so the plates are flush with each other. 90º Figure 23 Open corner joint plate alignment 50 FOUNDATION AND APPRENTICESHIP LEVELS 1 AND 2

Practical Competency P4-12 (Line D-D6) 5. Weld the joint in the sequence shown (Figure 26). Take care to avoid excessive buildup by adjusting your rate of travel and electrode angle as necessary. Be sure the legs of the fillet weld are equal in length. 3 2 1 Figure 26 Completed multi-pass fillet weld on an open corner joint in the 2F position 6. Clean up your weldment by removing the slag and spatter with a chipping hammer and wire brush. 7. Show your work to your instructor. He/she will evaluate it for: correct alignment good penetration good fusion absence of porosity absence of undercut overall appearance absence of arc strikes reasonable smoothness absence of irregularities legs of equal length slightly convex profile 8. Repeat the procedure using the E4918 (E7018) and E4924 (E7024) electrodes. 52 FOUNDATION AND APPRENTICESHIP LEVELS 1 AND 2

Practical Competency P4-12 (Line D-D6) P4-12 Learning Task 3: Fillet welds in the vertical (3F) uphill position on lap, tee and corner joints on low-carbon steel plate To complete this Learning Task, you must perform the following welding procedures: Procedure 3A: Single-pass fillet welds on lap joints in the 3F uphill position Procedure 3B: Multi-pass fillet welds on tee joints in the 3F uphill position Procedure 3C: Multi-pass fillet welds on corner joints in the 3F uphill position BC WELDER TRAINING PROGRAM 53

Practical Competency P4-12 (Line D-D6) WPS P4-12-3A: Single-pass fillet welds on lap joints in the 3F uphill position Materials Base metal Two pieces of low-carbon steel plate 10 mm or 13 mm ( 3 8" or 1 2") thick by 200 mm (8") wide Filler metal E4310/E4311 (E6010/E6011), 4 mm ( 5 32") diameter E4918 (E7018), 3.2 mm ( 1 8") diameter Welding symbol Polarity DCEP DCEP SMAW Directions 1. Position your two plates to make a lap joint (Figure 27). Overlap the plates no more than one thickness. Make sure the plates are tight together. Align the ends of the joint so the plates are flush with each other. 2. Select the correct polarity and current settings for the E4310/E4311 (E6010/E6011) electrode. Secure the ground clamp to your workpiece. Insert the electrode in the electrode holder. 3. Make four tack welds 19 mm ( 3 4 in.) long, one at each end of the joint and another two on the opposite side of the joint. 54 FOUNDATION AND APPRENTICESHIP LEVELS 1 AND 2

Practical Competency P4-12 (Line D-D6) 4. Place the joint in the 3F position (Figure 27). Figure 27 Lap joint in the 3F position 5. Travelling uphill, weld the joint completely using one pass only (Figure 28). Watch for excessive buildup or undercut. Adjust your rate of travel and electrode angle as necessary. Be sure the legs of the fillet weld are equal in length. Figure 28 Completed fillet weld on a lap joint in 3F position BC WELDER TRAINING PROGRAM 55

Practical Competency P4-12 (Line D-D6) 6. Clean up your weldment by removing the slag and spatter with a chipping hammer and wire brush. 7. Show your work to your instructor. He/she will evaluate it for: correct alignment good penetration good fusion absence of porosity absence of undercut overall appearance absence of stray arcs reasonable smoothness absence of irregularities legs of equal length slightly convex profile 8. Repeat the procedure using the E4918 (E7018) electrode. 56 FOUNDATION AND APPRENTICESHIP LEVELS 1 AND 2

Practical Competency P4-12 (Line D-D6) BC WELDER TRAINING PROGRAM 57

Practical Competency P4-12 (Line D-D6) WPS P4-12-3B: Multi-pass fillet welds on tee joints in the 3F (uphill) position Materials Base metal Two pieces of low-carbon steel plate 10 mm or 13 mm ( 3 8" or 1 2") thick by 200 mm (8") wide Filler metal E4310/E4311 (E6010/E6011), 3.2 mm ( 1 8") diameter E4310/E4311 (E6010/E6011), 4 mm ( 5 32") diameter E4918 (E7018), 3.2 mm ( 1 8") diameter E4918 (E7018), 4 mm ( 5 32") diameter Welding symbol Polarity DCEP DCEP DCEP DCEP SMAW Directions 1. Position your two plates to make a tee joint. Set the vertical piece two thicknesses in from the edge of the bottom plate. Make sure that the bottom plate lies flat on the work surface and the vertical plate forms the tee at 90 to the bottom plate. Align the ends of the joint so the plates are flush with each other. 2. Select the correct polarity and current setting for the E4310/E4311 (E6010/E6011) 3.2 mm ( 1 8 in.) diameter electrode. Attach the ground clamp to your workpiece. Insert the electrode in the electrode holder. 3. Make four tack welds 19 mm ( 3 4 in.) long, one at each end of the joint and another two on the opposite side of the joint. 4. Place the tee joint in the 3F position (Figure 29). 58 FOUNDATION AND APPRENTICESHIP LEVELS 1 AND 2