METAL FABRICATION

1. WELDING
(PROCESS AND MANAGEMENT)

4. – 1. Arc welding uses electricity to heat and
melt the metal.
– 2. A Weldor is the person doing the
welding.
Welding
A process of joining two
similar metal pieces by
heating to a fluid state
(melting), with or
without filler material or
pressure.

5. COMMON TYPES OF
WELDING
• METAL INERT GAS WELDING (MIG)
• GAS METAL ARC WELDING (GMAW)
• TUNGSTEN INERT GAS WELDING (TIG/GTAW)
• FLUX CORED ARC WELDING (FCAW)
• RESISTANCE SPOT WELDING (RSW)
• PLASMA ARC WELDING
• WATER PLASMA ARC WELDING/SUBMERGED WELDING
• STUD WELDING
• OXY ACETYLENE WELDING
• LASER WELDING
• BRAZING
• SOLDERING

6. "a career in-demand for 2013 and
beyond“
Welding?

7. SMAW PRINCIPLES
• The American
Welding Society
defines SMAW as
Shielded Metal
Arc Welding
• SMAW:
– Is commonly known
as ‘Stick’ welding or
manual metal arc
welding
– Is the most widely
used arc welding
process in the world

8. What are the
parts of a
welding machine?

9. TERMS and DEFINITIONS
• Base Metal- To be cut or welded.
• Arc- Flow of current across a narrow gap, usually
from the tip of the electrode to the base metal.
• Fusion process- a process of heating metal to a
molten state and allowing it to cool.
• Arc welding- joining together of two or more pieces
of metal by the fusion process.

10. Crater- depression at the termination
of a weld
Electrode- metal rod which conducts a
current from the electrode holder to
the base metal.
Bead weld- a weld made by one pass of
an electrode.
Bevel- angular cut made on the
vertical edge to allow better weld
penetration.

11. Butt joint- weld between two metal joints
on the same plane.
Tack weld- a weld made to hold parts in
proper alignment until the final welds are
made.
Puddle- that portion of a weld that is
molten at the place the heat is supplied.

12. 1- The Electrode
• Is a consumable - it gets
melted during the welding
process
• Is composed of two parts
– Core Rod (Metal Filler)
 Carries welding current
 Becomes part of the weld
– Flux Coating
 Produces a shielding gas
 Can provide additional filler
 Forms a slag

13. 2- The Arc
• An arc occurs when the
electrode comes in
contact with the work-
piece and completes the
circuit … like turning on a
light!
• The electric arc is
established in the space
between the end of the
electrode and the work
• The arc reaches
temperatures of 10,000°F
which melts the electrode
and base material
Can you identify the weld joint
and position being used?

14. 3- Weld Puddle
• As the core rod, flux
coating, and work
pieces heat up and
melt, they form a
pool of molten
material called a
weld puddle
• The weld puddle is
what a welder
watches and
manipulates while
welding
1/8” E6013 at
125 Amps AC

15. 4- Shielding Gas
• A shielding gas is
formed when the flux
coating melts.
• This protects the
weld puddle from
the atmosphere
preventing
contamination
during the molten
state
The shielding gas protects the molten
puddle from the atmosphere while
stabilizing the arc
2
3
Shielding Gas
4

16. 5- Solidified Weld
Metal
• As the molten weld
puddle solidifies, it
forms a joint or
connection between
two pieces of base
material
• When done properly
on steel, it results in a
weld stronger than the
surrounding base
metal

17. 6- Slag
• Slag is a combination of the flux
coating and impurities from the
base metal that float to the
surface of the weld.
• Slag quickly solidifies to form a
solid coating
• The slag also slows the cooling
rate of the weld
• The slag can be chipped away
and cleaned with a wire brush
when hard
This welder chips the slag off of a
weld during the repair of railroad
tracks

18. Application Activity
1
2
3
4
5
6
Let’s review the SMAW process …
• 1 = __________
• 2 = __________
• 3 = __________
• 4 = __________
• 5 = __________
• 6 = __________

19. SMAW Equipment Set Up
1. Turn power supply on
2. Connect work clamp
3. Select electrode
a. Type
b. Diameter
4. Adjust output
a. Polarity
b. Amperage
6. Insert electrode into electrode
holder

20. Arc Length
• After striking the arc, maintain a 1/8” distance
between the electrode and the workpiece
– If the arc length becomes too short, the electrode will
get stuck to the workpiece or ‘short out’
– If the arc length becomes too long; spatter, undercut,
and porosity can occur
Arc Length = 1/8”

21. Travel Speed
• The travel speed is the
speed at which the
electrode moves along
the base material while
welding
– Too fast of a travel speed
results in a ropey or
convex weld
– Too slow of a travel
speed results in a wide
weld with an excessive
metal deposit
The travel speed impacts the
shape of the bead.
End of Weld

22. Filling the Crater
• At the end of the weld, the operator
breaks the arc which creates a ‘crater’
• Use a short pause or slight back step at
the end of the weld to fill the crater
• Large craters can cause weld cracking
Back stepping is a
short move in the
opposite direction of
weld travel

23. Advantages of SMAW
• Low initial cost
• Portable
• Easy to use outdoors
• All position
capabilities
• Easy to change
between many base
materials
What safety precautions should
be taken by these welders?

24. Limitations of SMAW
• Lower consumable
efficiency
• Difficult to weld very
thin materials
• Frequent restarts
• Lower operating factor
• Higher operator skill
required for SMAW
than some other
processes Building a barge in a large shipyard

25. E70XX
Electrode
Tensile in psi
Welding Position:
Type of Current and Coating
AWS Classification
of SMAW Electrodes

26. SMAW Lesson #1
• Objective: Strike and establish an arc
• Equipment:
– SMAW machine
– Electrode (E6013)
– PPE
• Material:
– Mild Steel Plate

27. SMAW Lesson #2
• Objective: To run a straight bead on flat plate and to fill the crater
• Equipment:
– SMAW machine
– Electrode (E6013)
– PPE
• Material:
– Mild Steel Plate
Good Poor

28. SMAW Lesson #3
• Objective: To run a bead with the whip technique
• Equipment:
– SMAW machine
– Electrode (E6013)
– PPE
• Material:
– Mild Steel Plate

29. SMAW Lesson #4
• Objective: To build a pass
• Equipment:
– SMAW machine
– Electrode (E6013)
– PPE
• Material:
– Mild Steel Plate

30. SMAW Lesson #5
• Objective: To make a fillet weld on a lap joint in the horizontal position
• Equipment:
– SMAW machine
– Electrode (E6013)
– PPE
• Material:
– Mild Steel Plate
Top View Side View

31. SMAW Lesson #6
• Objective: To make a fillet weld on a tee joint in the horizontal position
• Equipment:
– SMAW machine
– Electrode (E6013)
– PPE
• Material:
– Mild Steel Plate

32. SMAW Lesson #7
• Objective: To make a fillet weld on a tee joint in the horizontal position
• Equipment:
– SMAW machine
– Electrode (E6013)
– PPE
• Material:
– Mild Steel Plate

33. SMAW Lesson #8
• Objective: To make a three pass fillet weld on a tee joint in the horizontal position
• Equipment:
– SMAW machine
– Electrode (E6013)
– PPE
• Material:
– Mild Steel Plate

34. SMAW Lesson #9
• Objective: To make a fillet weld on a lap joint in the vertical position welding down
• Equipment:
– SMAW machine
– Electrode (E6013)
– PPE
• Material:
– Mild Steel Plate

35. SMAW Lesson #10
• Objective: To make a fillet weld on a tee joint in the vertical position welding down
• Equipment:
– SMAW machine
– Electrode (E6013)
– PPE
• Material:
– Mild Steel Plate

36. SMAW Lesson #11
• Objective: To make a fillet weld on a lap joint in the overhead position
• Equipment:
– SMAW machine
– Electrode (E6013)
– PPE
• Material:
– Mild Steel Plate

37. SMAW Lesson #12
• Objective: To make a fillet weld on a tee joint in the overhead position
• Equipment:
– SMAW machine
– Electrode (E6013)
– PPE
• Material:
– Mild Steel Plate

38. SMAW Lesson #13
• Objective: To make a single pass fillet weld on a tee joint in the vertical position
welding up
• Equipment:
– SMAW machine
– Electrode (E6013)
– PPE
• Material:
– Mild Steel Plate

39. SMAW Lesson #14
• Objective: To make a three pass fillet weld
on a tee joint in the vertical position welding
up
• Equipment:
– SMAW machine
– Electrode (E6013)
– PPE
• Material:
– Mild Steel Plate

40. SMAW Lesson #15
• Objective: To make a single pass fillet weld on a tee joint in the vertical position
welding up
• Equipment:
– SMAW machine
– Electrode (E6013)
– PPE
• Material:
– Mild Steel Plate

41. SMAW Lesson #16
• Objective: To make a three pass fillet weld
on a tee joint in the vertical position welding
up
• Equipment:
– SMAW machine
– Electrode (E6013)
– PPE
• Material:
– Mild Steel Plate

42. 42
Five (5) Common Power
Supplies
• Transformer
– AC only
• Rectifier
– DC only
• Transformer/rectifier
– AC or DC
• Generator
– DC and/or AC
• Inverter
– AC and DC

43. Tools and Equipment
Power Supply Polarity Switch
Electrode
Base Metal
(work Piece)
Ground Clamp
Ground Cable
Amperage
Scale
Power Switch
Amperage
Adjustment
Electrode Cable
Electrode Holder
Power
Cord
Chipping hammer
Wire brush
Pliers
Hacksaw
Power sanderHERE ARE
THE PARTS

44. MEANINGS OF NUMBERS IN THE
ELECTRODE
• E- Stands for Electric arc welding
• First two digits- indicate tensile
strength deposited in thousand
pounds per square inch.
• Third digit- indicates welding position:
- “1” indicates all position
- “2” indicates flat and horizontal only
- “3” indicates flat only
- “4” indicates flat, horizontal, vertical
down, overhead
• Fourth or last digit- represents special
characteristics and usability of the
electrode.

45. Welding - Personal Protective Equipment
Body Part Equipment Illustration Reason
Eyes and face Welding helmet, hand shield,
or goggles
Protects from:
•radiation
•hot slag, sparks
•intense light
•irritation and chemical burns
Lungs (breathing) Respirators Protects against:
•fumes and oxides
Exposed skin (other than
feet, hands, and head)
Fire/Flame resistant clothing
and aprons
Protects against:
•heat, fires, burns
Ears - hearing Ear muffs, ear plugs
Protects against:
•noise
Feet and hands Boots, gloves Protects against:
•electric shock, heat, burns,
fires

46. Arc Welding PPE
• Helmet
– Shade 10 or darker
– Face protection
– Always wear safety glasses underneath
– Auto helmet recommended
• Clothing
– Long sleeves
– Button up shirt
– Work shoes
– Protective apron, sleeves, jackets or pants if available. (Fig 26-6)

47. Safety Comes First
-Do not look at the arc without eye protection.
-Wear a head or face shield that is in good
condition.
-Wear suitable clothing to protect all parts of
the body.
Examples: Long-sleeved shirt, leather gloves,
high top shoes or boots, buttoned down collar.

48. Safety
• -Do not strike an arc or weld until you are
sure those in the vicinity have protective
equipment or will look the other direction.
Note: Shout “Cover” before striking an arc.
-Do not weld around combustible and
flammable materials.
-Do not pick up hot metal.
-Do not weld in confined places without
proper ventilation

49. • -Open main switch or disconnect plug
when checking a welder.
-Do not leave electrode holder on welding
table or in direct contact with grounded
metal.
-Do not use worn or frayed cables.
-Stand on dry footing when welding
-Keep areas around welder clean.
-Keep tools and metals in proper location.
Safety

50. Arc Welding Safety
1. Recognize that arc welding produces a lot of
heat.
2. Use equipment according to manufacturers
recommendations.
3. Insure fire extinguishers are available
4. Provide a first aid kit
5. Use water filled containers to receive hot metal
from cutting operations.
6. Practice good housekeeping
7. Use appropriate PPE

51. Arc Welding Safety-cont.
7. Insure all wiring is correctly installed and maintained.
8. Remove or shield all combustible materials in work area.
9. Do not use gloves or clothing which contain flammable
substances
10. Protect others from arc flash.
11. Protect equipment from hot sparks.
12. Use a fume collector.
13. Never work in damp or wet area.
14. Shutoff power source before making repairs or
adjustments, including changing electrode.
15. Don’t overload the welding cables or use cables with
damaged insulation.

52. • Fumes and Gases can be dangerous
– Keep your head out of the fumes
– Use enough ventilation, exhaust at the arc, or both, to keep fumes and gases
from your breathing zone and the general area
– The SMAW process can withstand wind and exhaust near the arc from ventilation
equipment
• Electric Shock can kill – to receive a shock your body must touch the electrode and
work or ground at the same time
– Do not touch the electrode or metal parts of the electrode holder with skin or wet
clothing
– Keep dry insulation between your body and the metal being welded or ground
• Arc Rays can injure eyes and skin - Choose correct filter shade (See chart below)

53. 53
Striking The Arc
• Select the best electrode
• Set the welder
• Turn on welder
• Warn bystanders
• Lower helmet
• Start arc (two methods)
– Brushing
– Tapping

54. 54
Brushing Method
 Hold end of electrode about 1/4 -
1/2 inch above the surface.
 Lower helmet
 Gently brush surface of the metal
with the end of the electrode.
 When arc starts, lift electrode 1/8
inch.
 If electrode sticks, twist it back and forth. If it does not break loose,
release electrode from electrode holder.
Do not shut off the welder with the electrode stuck to the metal.
Recommended method for beginning weldors.

55. 55
Tapping Method
• Set up welder
• Hold the electrode
at the travel angle
and 1/4 - 1/2 inch
above the metal.
• Quickly lower the
electrode until it
touches the metal
and then lift it 1/8
inch.

56. 56
SMAW Process
1
Travel direction
Electrode
Arc2
Weld Puddle 3
Shielding Gas
4
Solidified Weld Metal5
Slag
6
Let’s take a little closer look at the SMAW
process…
1
Travel direction
Electrode
Arc2
Weld Puddle3
Shielding Gas
4
Solidified Weld Metal5
Slag
6

57. Arc Welding Bead Nomenclature
Flux Electrode
Electrode
metal
Penetration
Molten
puddle
BeadBase metal
Slag
Gas
shield

58. SMAW
Process
• The arc temperature over 9,000 o
F melts the base
metal, the wire core and the coating on the
electrode.
• The high temperature causes some of the
ingredients in the flux to form a gaseous shield.
• The electric energy is provided by a special power
source.
• As the weld cools slag forms on top of the weld
puddle.

59. Running Beads
• Practice running stringer beads
– No weaving or pattern.
– Remember the electrode burns off as the weld is made.
• Speed used should result in a bead 2-3
times wider than the diameter of the
electrode.
• Cool metal between beads.
• Practice holding a long arc for a couple
of seconds after striking the arc.
– Preheats the weld
• Practice filling in the crater.

60. Five (5) Factors of Arc Welding
1.Heat
2.Electrode
3.Electrode angle
4.Arc length
5.Speed of travel

61. Five (5) Factors
1. Heat• The arc welder must produce sufficient heat (electric arc) to melt the
electrode and the base metal to the desired depth.
• The amount of heat produced is determined by the amperage.
– Amperage is limited by the diameter of the electrode and the capacity of the
welder.
• The amount of heat needed to complete the weld is determined by
several factors:
 Excessive heat.
 Electrode easier to
start
 Excessive penetration
(burn through)
 Excessive bead width
 Excessive splatter
 Electrode overheating
 Insufficient heat.
 Hard to start
 Reduced
penetration
 Narrow bead
 Coarse ripples
 Thickness of the
metal
 Type of joint,
 Electrode type
 Electrode
diameter
 Weld position

62. Five (5) Factors
2. Electrodes• The SMAW process uses a
consumable electrode.
– Electrode must be
compatible with base
metal.
• Electrodes are available for
different metals.
– Carbon steels
– Low alloy steels
– Corrosion resisting
steels
– Cast irons
– Aluminum and alloys
– Copper and alloys
– Nickel and alloys
 Another useful group of
electrodes is
hardsurfacing.
 NEMA color coding
 System of of colors on the
end or dots on the bare
wire indicating the class of
electrode.
 Not very common today.
 AWS numerical coding
 Most popular method.

63. Welding Currents
• Not all electrodes are designed to work
with all currents.
• Common SMAW currents.
– Alternating Current (AC)
– Direct Current straight polarity (DCSP) or (DCEN)
– Direct Current Reverse polarity (DCRP) or (DCEP)

64. Arc Welding Electrode Flux
• Flux: A material used during arc welding, brazing or braze welding to clean the
surfaces of the joint chemically, to prevent atmospheric oxidation and to reduce
impurities and/or float them to the surface. (British Standard 499)
• Seven (7) Classifications of Flux constituents
1. Protection from atmospheric contamination
2. Fluxing agents
3. Arc initiators and stabilizers
4. Deoxidizes
5. Physical properties of the flux
6. Fillers and metallic additions
7. Binders and flux strength improvers

65. Electrode Grouping
• Electrodes are also grouped according to there
performance characteristics.
– Fast-freeze
• Mild steel
• Quick solidification of weld pool
• Deep penetrating
• Recommended for out of position
welds
• Deep penetrating arc
– Fast-fill
• Highest deposition rate
• Stable arc
• Thick flux
• Flat position and horizontal laps only
- Fill-freeze
• General purpose electrodes
• Characteristics of fast-freeze
and fast-fill
 Low hydrogen
• Welding characteristics of fill-
freeze
• Designed for medium carbon
and alloy steels

66. Electrode Storage
• Electrodes are damaged by rough treatment, temperature
extremes and moisture.
• The should be kept in their original container until used.
• They should be stored in a heated cabinet that maintains them
at a constant temperature.
• The storage of low hydrogen electrodes is very critical.
– Designed to reduce underbead cracking in alloy and
medium carbon steels by reducing the the amount of
hydrogen in the weld pool.
– The flux is hydroscopic--attracts moisture (H2O).
– Moisture in the flux also causes excessive gasses to
develop in the weld pool and causes a defect in the weld
caused worm holes.

67. 67
Five (5) Factors
3. Electrode Angle
• The electrode angle influences
the placement of the heat.
• Two angles are important:
– Travel
– Work
 The correct travel angle must be used for each joint.
 Beads = 15o
from vertical or 75o
from the work.
 Butt joint = 15o
from vertical or 75o
from the work.
 Lap joint = 45o
.
 T joint = 45o
.
 Corner = 15o
from vertical or 75o
from the work.

68. Five (5) Factors
Electrode Angle-cont.
 The work angle is the angle of the
electrode perpendicular to the
joint.
 Beads = 90o
 Butt joint = 90o
 Lap joint = 45o
 T joint = 45o
 Corner = 90o
 The appropriate angle must be used for
each joint.
 The work angle may need to be
modified for some situations.
 For example, a butt joint with two
different thickness of metal.

69. Five (5) Factors
4. Arc Length• The arc length is the distance from the metal part of the
electrode to the weld puddle.
• The best arc length is not a fixed distance, but should be
approximately equal to the diameter of the electrode.
 Arc length can be adjusted slightly to
change the welding process.
 Excessive length
 Excessive spatter
 Reduced penetration
 Poor quality weld
 Insufficient length
 Electrode sticks
 Narrow weld
 Poor quality weld

70. Five (5) Factors
5. Speed of Travel
• The speed of travel (inches per minute) is
an important factor when arc welding.
• The best speed of travel (welding speed)
is determined by several factors:
– The size of the joint,
– The type of electrode
– The size of the electrode
– The amperage setting on the machine
– Deposition rate of the electrode (cubic inches per minute)
• The deposition rate of an electrode will
change with the welding amperage.

71. Five (5) Factors
5. Speed-cont.
• The ideal speed can be
calculated using the volume of
the joint and the deposition rate
of the electrode.
Area =
1
2
bh =
0.25 in x 0.25 in
2
= 0.0625 in2
 Step one: determine the area of
the weld. (Assuming 1/16 inch
penetration.)
 Step Two: knowing the deposition rate of the electrode,
determine the welding speed. (Deposition rate = 2.5
in3
/min.)
in
min
=
2.5 in3
min
x
1
0.0625 in2
= 40
in
min

72. Five (5) Factors
5. Speed-cont.
• The correct welding speed is indicated by the shape
of the ripples.
Too fast = narrower width,
elongated ripple pattern,
shallow penetration.
Recommended = width 2-3
times diameter of electrode,
uniform ripple pattern, full
penetration.
Too slow = excessive width,
excessive penetration

73. Common SMAW Defects
• Undercutting
– improper welding
parameters; particularly the
travel speed and arc voltage.
• Porosity
– Atmospheric contamination
or excess gas in the weld
pool.
 Hot cracks
 Caused by excessive contraction
of the metal as it cools.
 Excessive bead size
 May also be found at the root of
the weld.
 Slag inclusions
 Long arc
 Incomplete removal of slag on
multipass welds.
Under Cutting
Hot Cracks
Slag Inclusions
Porosity

74. SMAW Weld Defects-cont.
 Toe Cracks
 Excessive heat and rapid cooling.
 Underbead cracks
 Excessive hydrogen in weld pool
 Microcracks
 Caused by stresses as weld cools.
 Incomplete fusion
 Incorrect welding parameters or welding techniques.
Toe cracks
Underbead cracks
Microcracks
Incomplete fusion

75. KINDS OF WELD
1.FILLE
T
2.GROO
VE
3.BEAD

76. 76
Weld Joints
Butt
Lap
Tee
Corner
Edge

77. Welding PositionsWelding Positions
FLATFLAT
HORIZONTALHORIZONTAL
VERTICALVERTICAL
OVERHEADOVERHEAD
INCREASING DIFFICULTY

78. 78
Work Angle
• The work angle is the
angle between the
electrode and the
work as depicted on
the left
• Work angles can vary
depending on the
position the weld is
being made.
90°

79. 79
Travel Angle
• Also commonly
called Lead Angle
• The travel (lead)
angle is the angle
between the
electrode and the
plane
perpendicular to
the weld axis
20-30°

80. Bead Pattern
• Stringer (drag) (whip)
• Weave
– Circles
– crescent
– zig zag
– box weave
– double J

81. Passes
• Weld Pass - A single progression of welding
along a joint. The result of a pass is a weld
bead or layer

82. Root Pass Hot Pass
Fill Pass Cover Pass

83. Reasons for Poor Weld
• Machine adjustment too high or too low
• Electrode size too large or too small
• Improper movement of electrode
• Improper angle of electrode
• Improper base metal preparation
• Arc length too long or too short

84. Shielded Metal Arc
Welding (SMAW)
Troubleshooting Welds

85. WHAT IS WELD DEFECT?
• Is any flaw that compromises the
usefulness of the welding.
• According to the American Welding
Society (AWS), welding defect causes are
broken down as follows: 45 percent poor
process conditions, 32 percent operator
error, 12 percent wrong technique, 10
percent incorrect consumables, and 5
percent bad weld grooves.

86. A B C D E F G

87. Porosity- small cavities or holes resulting from gas pockets
in weld metal.
Possible Causes Corrective Actions
Arc length too long. Reduce arc length.
Workpiece dirty. Remove all grease, oil, moisture, rust, paint,
coatings, slag, and dirt from work surface before welding.
Damp electrode. Use dry electrode.

89. Pinhole

90. Excessive Spatter
Excessive Spatter − scattering of molten metal
particles that cool to solid form near weld bead
Possible Causes Corrective Actions
Amperage too high for electrode.
Decrease amperage or select larger electrode.
Arc length too long or voltage too high.
Reduce arc length or voltage.

92. Incomplete Fusion
Incomplete Fusion − failure of weld metal to fuse
completely with base metal or a preceeding weld bead.
Possible Causes Corrective Actions
Insufficient heat input. Increase amperage. Select larger electrode
and increase amperage.
Improper welding technique. Place stringer bead in proper
location(s) at joint during welding.
Adjust work angle or widen groove to access bottom during welding.
Momentarily hold arc on groove side walls when using weaving
technique.
Keep arc on leading edge of weld puddle.
Workpiece dirty. Remove all grease, oil, moisture, rust, paint,
coatings, slag, and dirt from work surface before welding.

94. Lack Of Penetration
Lack Of Penetration − shallow fusion between weld metal and base
metal.
Lack of Penetration Good Penetration
Possible Causes Corrective Actions
Improper joint preparation. Material too thick. Joint preparation and
design must provide access to bottom of groove.
Improper weld technique. Keep arc on leading edge of weld puddle.
Reduce travel speed.
Insufficient heat input. Increase amperage. Select larger electrode
and increase amperage.

96. Excessive Penetration
Excessive Penetration − weld metal melting through
base metal and hanging underneath weld.
Possible Causes Corrective Actions
Excessive heat input. Select lower amperage. Use smaller
electrode.
Improper weld technique. Adjust travel speed

99. Burn-Through
Burn-Through − weld metal melting completely through
base metal resulting in holes where no metal remains.
Possible Causes Corrective Actions
Excessive heat input. Select lower amperage. Use smaller
electrode.
Increase and/or maintain steady travel speed.

101. Waviness Of Bead
Waviness Of Bead − weld metal that is not parallel and does not
cover joint formed by base metal.
Possible Causes Corrective Actions
Unsteady hand. Use two hands. Practice technique

103. Distortion
Distortion − contraction of weld metal during welding that
forces base metal to move.
Base metal moves in the direction of the weld bead.
Possible Causes Corrective Actions
Excessive heat input. Use restraint (clamp) to hold base metal in
position.
Make tack welds along joint before starting welding operation.
Predict anticipated weld distortion and precamber base metal.
Select lower amperage for electrode.
Increase travel speed.
Weld in small segments and allow cooling between welds.

105. 1.STRONG WORK ETHIC
2.DEPENDABILITY AND
RESPONSIBILITY
3.POSSESSING A POSITIVE ATTITUDE
4.ADAPTABILITY
5.HONESTY AND INTEGRITY
6.SELF MOTIVATED
7.MOTIVATED TO GROW AND LEARN
8.STRONG SELF CONFIDENCE
9.PROFESSIONALISM
10.LOYALTY

106. 1. Strong Work Ethic
Employers value employees who understand and possess a willingness
to work hard. In addition to working hard it is also important to work smart.
This means learning the most efficient way to complete tasks and
finding ways to save time while completing daily assignments.

107. 2. Dependability and Responsibility
Employers value employees who come to work on time, are there when
they are suppose to be, and are responsible for their actions and behavior.
It’s important to keep supervisors abreast of changes in your schedule
or if you are going to be late for any reason.

108. 3. Possessing a Positive Attitude.
Employers seek employees who take the initiative and have the motivation
to get the job done in a reasonable period of time.
A positive attitude gets the work done and motivates others to do the same
without dwelling on the challenges that inevitably come up in any job.

109. 4. Adaptability
Employers seek employees who are adaptable and maintain
flexibility in completing tasks in an ever changing workplace.
Being open to change and improvements provides an opportunity to
complete work assignments in a more efficient manner while offering
additional benefits to the corporation, the customer, and even the employee.

110. 5. Honesty and Integrity
Employers value employees who maintain a sense of honesty and integrity
above all else. Good relationships are built on trust.
When working for an employer they want to know that they can trust
what you say and what you do.

111. 6. Self – Motivated
Employers look for employees who require little supervision and direction
to get the work done in a timely and professional manner. Supervisors who
hire self-motivated employees do themselves an immense favor.

112. 7. Motivated to Grow & Learn
In an ever-changing workplace, employers seek employees who are interested
in keeping up with new developments and knowledge in the field.
It has been noted that one of the top reasons employees leave their employers
is the lack of opportunity for career development within the organization.

113. 8. Strong Self – Confidence
Self-confidence has been recognized as the key ingredient between someone
who is successful and someone who is not. A self – confident person is
someone who inspires others. A self-confident person is not afraid to
ask questions on topics where they feel they need more knowledge.

114. 9. Professionalism
Employers value employees who exhibit professional behavior at all times.
Professional behavior includes learning every aspect of a job and doing it to
the best of one’s ability. Professionals look, speak, and dress accordingly to
maintain an image of someone who takes pride in their behavior and appearance.

115. 10. Loyalty
Employers value employees they can trust and who exhibit their loyalty to
the company. Loyalty in the workforce has taken on a new meaning.
Gone are the days when employees plan on starting out and retiring
with the same company.

117. • It was only in the early 1980s that
good housekeeping became a
pertinent issue in Japanese
industries, as companies realized
its powerful contribution to
productivity and quality
improvement.

118. • The basis for good housekeeping
in Japanese companies is a
concept popularly known as 5S.
This stands for five good
housekeeping concepts in
Japanese.

119. Why good housekeeping?
Good housekeeping
promotes
Quality
Safety Productivity
Clean
Environment

120. 5 “S” Japanese English
1 S Seiri Sort out unnecessary items in the workplace
and discard them.
2 S Seiton Arrange necessary items in good order.
3 S Seiso Clean your workplace thoroughly so that
there is no dust on floors, machines and
equipment.
4 S Seiketsu Maintain high standards of housekeeping at
workplace at all times.
5 S Shitsuke Train people to follow good housekeeping
disciplines.

121. SEIRI
• SORT OUT THE ITEMS AND DISCARD THE
UNWANTED
– Make a list of all the items in the department.
– The list should include raw material, wip, finished
product, tools, tackles, dust bin, facilities like chair,
table, bins etc. nothing should be left unlisted.
– Appropriate authority should decide which items
can be disposed off and which items need to be
kept in the department.
– Items marked for disposal should be disposed off
in a safe manner.

122. SEITON
• PLACE FOR EVERY THING
– After disposing unwanted material, provide
appropriate place for every item that has to be
kept in the department.
– While providing the place the ergonomic factors
and safety aspects have also to be considered.
– Place for movement of men and material should
also be provided.
– Place should be distinctly identified and marked.
– Place for display of instructions, posters etc.
should lso be identified.

123. SEISO
• CLEAN THE PLACE THOROUGHLY AND
KEEP EVERY THING IN IT’S PLACE.
– Clean every thing including material, floor,
containers, walls, windows etc.
– If necessary painting also should be done.
– While painting follow colour codes wherever
applicable.
– Insist on regular cleaning at the end of the work

124. SEIKETSU
• Maintain high standards of housekeeping at
workplace at all times.
– Ensure that people keep the items at
designated place after it’s use.
– If possible, design the system such that if
some thing is missing from the place, it is
easily highlighted

125. SHITSUKE
• Train people to follow good housekeeping
discipline.
– Train people in 5 S, housekeeping etc.
– Lead by example.
– Maintain discipline in every aspect