1

CHAPTER 1

THE PROBLEM AND ITS SETTING

Introduction

The researchers are experiencing being welder for their first time

many encounter problems should be feeling uncomfortable. This situation is not

easy to handle because of emotions we feel afraid, shocked, nervous, etc.

Eventually you have to do something that simply identifies what is the better

action. Some student-welder has no idea what is right or correct like how too

straight your bead in a steel plate? How to maintain the length of the arc? What

is correct amperage, size of electrode, angle of arc? This is the common problem

encountered on the situation to understand what the welding process is.

The first problem is the lack of knowledge. Lack of knowledge is

ignorance the word "ignorant" is an adjective that describes a person in the state

of being unaware, and can describe individuals who deliberately ignore or

disregard important information or facts, or individuals who are unaware of

important information or facts. Ignorant, illiterate, unlettered, uneducated mean

lacking in knowledge or training. Ignorant may mean knowing little or nothing, or

it may mean uninformed about a particular subject. And the question is why it is a

problem? For example, your welding instructor told you what is the correct

amperage of 6011 electrodes, 6013 electrodes, and 7018 electrodes and then

you said I don’t know. It is a lack of knowledge you are not aware confront the
 2

fact that must be known if you are a welder. What do you think? The result of

your work output welding activity. Actually, it is disorderly.

The second problem is the lack of practice. Lack of practice does not

prepare and carry out negotiations, particularly simulation; those most face

where there is almost no time for improvisations. Lack of Practice means doing

something not regularly to be able to do it better practice is one of these periods

of doing something. And then the question is why it is a problem? For example,

the daily routine of the welder is practicing their hands of muscle memory like an

artist always practice to pursue regular draw in his/her paper to become better

not to become perfect but because perfectionism is destroyed the motivation

itself. All you have to do expose yourself to the activity you want to do

specialization. If you want to improve in welding you practice, practice and

practice apply the “spaced of repetition” in scientific explanation is that an

evidence-based learning technique that is usually performed with flashcards.

Newly introduced and more difficult flashcards are shown more frequently while

older and less difficult flashcards are shown less frequently to exploit the

psychological spacing effect.

The solution for those problems in practical skills among IA welding

student proposed “Intervention Program” for SMAW practical skills. This solution

will be successful to SMAW grade 11 students can make a difference for

struggling students and help them get back on track. With so much recent

research on student intervention as well as trends that seem to pop up every

minute, it can be hard to determine what truly makes an intervention program

 3

effective. Leveraging data is the key to understanding where your students are

struggling in a particular objective, and it can be a regular and consistent way to

determine their level understanding. Aligning data with your instructional goals or

intervention objectives can help you take your students to the next level.

Assessments typically serve two different purposes: to monitor student progress

and to identify students who are at risk. Performance on various assessments

should be used to identify targeted interventions for different student groups and

to determine if students in those groups are making the expected progress.

Programs can be used to help prescribe content for your students so that you

can spend more time working directly with them in subjects they are struggling

with.

As they practiced remember to be patient as they learn. The goal is not

to learn frustrated by the shortcomings or mistakes but to press on through the

challenges and setbacks as you learn and better new skills. As you put into the

time all practice; the step closer to repetition. Welder’s practice the same tasks

repeatedly until the processes become a better welder and they consistently get

require you to take on a variety of welding activities or tasks and rehearse the

same processes again and again until the outcome is satisfactory to them and

their instructors.

Welding can be learned with time and effort, fortunately, like any other trade

skills. So instead of asking why it is so difficult to be in the welding strand, have

 4

much time and effort must do. Seriously solve the problem in a solution of

implemented the proposed intervention program for SMAW practical skills to

everyone welder student grade 11 to help the increase not to decrease the level

of practical skill in SMAW subject to become confidently as a student welder.

Setting of the Study

The study will be conducted at Buting Senior High School located A.

Santos St. Buting Pasig City. A welding laboratory is a place wherein happen to

practice and train the IA-SMAW student grade 11 to improve the practical skills of

specialization. Buting Senior High School is an independent public senior high

school located in Buting, Pasig City recognized by the Department of Education

(DepEd). The school provides all strands of the Academic Track as well as the

Technical Vocational Livelihood (TVL) track for its senior high school program.

The study of research conducted in Buting Senior High School is to know the

level of practical skills subject in SMAW among grade 11 IA welding student

purposed intervention program.

 5

Research Locale

They will decided to conduct our research in Buting Senior High School,

Buting Senior High School is an independent public senior high school located in

Buting, Pasig City recognized by the Department of Education (DepEd). The

school provides Technical Vocational Livelihood (TVL) track for its senior high

school programs as well as IA-SMAW this is the reason why to choose partake

the survey in Buting Senior High School because is related to the study.

Figure 1 Map of Buting Senior High School

 6

Conceptual Framework

Process Output
Input
1.Shielded
2.Practical
Metal ARC skill
WELDING 2.1 Student “Proposed
1.1 Five 2.2 Intervention
Essentials of strand/grade program for
welding level SMAW
1.2 Welding 2.3
Manipulation Practical
Attendance
1.3 Welding Skills”
2.4 Gender
Position
1.4 Welding 2.5 Ages
Discontinuity

The input components of Shielded Metal Arc Welding subject

knowledge composed of five essentials of welding reference to welding

manipulation compose of grade 11 welding position and the welding

discontinuity. Review according to the process is student, strand grade level,

 7

attendance, gender, and age. The problem that we focus to solve is competence

level, knowledge level, and skill level. The output is the Proposed Intervention

program for SMAW Practical Skills.

STATEMENT OF PROBLEM

This study aims to determine the Level of Practical Skills in SMAW Grade

11 IA Welding Students the result will be the basis for and development of an

intervention program that may help improve the skills of the respondents SMAW

students.

1. What is the Demographic profile of the SMAW students?

1.1 Grade-11/ IA-SMAW Strand

1.2 Gender

1.3 Attendance (Monthly)

2. What is the grade level and strand of student to be selected to perform the

practical skills in welding?

2.2 Grade 11 IA welding students

3. What are the practical skills in welding that the SMAW students perform?

3.1 1F (Flat Position)

3.2 2F (Horizontal Position)

3.3 3F (Vertical Position)

 8

3.4 4F (Overhead Position)

4. What is the intervention that will be developed according to the competency

needed among the welding student of Buting Senior High School?

Significance of the Study

The results of this research may have a valuable contribution to the

following.

To Grade 11 IA-SMAW Students- The study will be significant to students from

this research because it gives ideas and knowledge to be easy to solve the

problem based on encountering difficulties on welding that increase the level of

practical skills and it can be aware how to find the solution in during welding.

To IA-SMAW Teacher- This research may help the IA-SMAW teacher to

determine the best strategy they need to do in teaching and perform the better

way to pay attention to the weakness of welder students.

To IA-SMAW Future Researcher- This will serve as a reference that may give

an idea or format of research. If they do not know how to make research

enumeration correctly and properly regarding the level of practical skills in SMAW

subject.

To School Administration- The study will be significant to school administration

from this research because to show the study that our partake of the researcher

will be accommodated wherein knowledge, strategies and techniques to

presenting strand TVL-IA welding BSHS.

 9

Scope and Limitation

The Scope of this study only focuses on the level of practical skills in

SMAW grade 11 IA welding students. The respondents are grade 11 IA-SMAW

students in Buting Senior High School S.Y. 2019-2020. This study is only limited

to grade 11 IA-SMAW students of Buting Senior High School because they are

the only strand who has a subject about practical skills in SMAW subject.

DEFINITION OF TERMS

Shielded Metal Arc Welding (SMAW) an arc welding process that uses an

electric arc, usually between a flux covered consumable electrode and the weld

pool.

Flux a material that produces a gaseous shield to protect the weld pool and to

stabilize the arc, making welding easier.

Current is the flow or movement of electric input into the welding machine.

Amperage is a setting on a welding machine or a measurement in the rate of

current flow.

Voltage is a measurement of the force causing the flow of electricity.

Alternating Current (AC) is back and forth motion of electric current.

Direct Current (DC) is electric current that flows in one direction.

 10

Hertz a unit of frequency equal to cycles per second.

Electrode Lead is a cable that connects an electrode to a power source.

Straight Polarity is to see electrode negative.

Negative Terminal is symbol in a machine (-)

Work piece connection is a cable that connects to the ground.

Electrode Negative is an electrode attached to the negative terminal and the

work piece connection attached to the positive terminal on the welding machine.

Reverse Polarity is to see positive.

Positive Terminal is a symbol in a machine (+)

Electrode Positive is electrode attached to the positive terminal and the work

piece connection attached to the negative terminal on the welding machine

Base Metal is a metal to be welded or cut.

Filler Metal is a metal added to a joint.

Weld Joint is a physical configuration of the joint members to be joined.

Weld Passes is progression of welding along a joint.

Electrode is coated metal wire which forms and cleans the weld bead.

Travel Speed is a speed at which the electrode is moved across the weld area.

Molten Pool is a liquid metal formed at the point of welding.

 11

Arc is a controlled short circuit by which electric current causes intense heat in a

weld pool between an electrode and base metal.

Spatter is a molten metal thrown out of the weld pool.

Fusion is melting and mixing together of the pieces that from the base metal with

and without filler metal.

Porosity is pinholes in a weld as the result of gas pocket.

1f also known as Flat position on tee- joint

2f also known as Horizontal position on tee- joint

3f also known as Vertical position on tee- joint

4f also known as Overhead position on tee- joint

CHAPTER 2

REVIEW RELATED AND LITERATURE

 12

This chapter presents the related literature and studies foreign sources only. This

includes many ideas and knowledge in practical skills in SMAW IA welding

student to give strong foundation of the topic.

According to the article NJR Steel article views 6118 categories

manufacturing, DIY how to weld procedure or process for beginner Safety the

first and most important thing to consider while using any sort of welder is safety.

Clean your metal it is still important to clean the area of the metal you plan on

welding. This is generally done with some sort of wire brush, grinder, or even

better, a grinder. Cut your metal an accurate cut starts with an accurate scribe, or

mark, on the work-piece. This is generally done with a soap stone or felt-tipped

pen and a ruler with a straight edge. Set up your work-piece it is time to get your

work-piece set up so that you can easily tack-weld it together without having to

fight with it too much. For mass production work, this is where you would typically

devise some sort of jig that would allow you to easily set your pieces into place

without having to think about it. Turn on the welder and adjust the settings as the

metal you are welding increases in thickness, you will want to increase the

voltage and wire speed as you see fit. It is always good to do a couple test welds

on some scrap metal to make sure your settings are right where they need to be

before you actually start on your project. Tack-weld the work-piece When tack

welding, it is important to make sure that you are actually fusing both sides of the

metal together. When you pull the trigger on the torch, pay attention to where you

are depositing the weld metal and that you are hitting the work-piece exactly

where one piece comes in contact with another. Fill in the remaining areas with
 13

‘bead’ welds this is where you will really get to hone in your welding skills, so pay

close attention to how your torch angle, travel speed, and electrical stick out

affect the appearance of your welds. Clean up your piece once you’ve removed

as much as you can by hand, grab your pair of locking pliers and clamp it to one

of the outside edges of the work-piece. Carefully use the bench grinder to grind

down your welds until you’ve basically removed the outer layers of your weld and

the corners are flush. Clean up the area you were working at and put all the tools

back where you found them. This will make your next welding session all the

more efficient. (http://www.njrsteel.com/how-do-i/article/how-to-weld-arc)

According to this web page Welding 101: Getting Familiar with the

Basics by Ed Learn Jan 12, 2011,) Welding can be an exciting hobby and very

rewarding profession. The applications in which welding can be used are

endless and there is a great deal of opportunities for proficient welders no matter

what the state of the economy. With advancements in welding technology,

welding can be done in just about any environment, including under water and in

outer space. As a refresher, welding is the process of joining two or more metal

parts by melting the pieces and adding filler material. The filler is melted and

pools between the other pieces. The end result after the materials cool is a

strong joint or weld. When it comes to traditional welding techniques, there are

three basic types. They are stick welding, metal inert gas (MIG), and tungsten

inert gas (TIG). These three welding types make up 90% of all welding done in

the world. Although there are more advanced welding processes, such as

plasma arc and laser welding, this is the right place to start for the beginning
 14

welder for the hobbyist or home shop welder, stick welding is the most popular

welding technique. An electric current pass between the metal and an electrode

(stick). The electrode melts and combines with the metal to form the joint. Stick

welding is easy to learn and the equipment required is relatively inexpensive

compared to other forms of welding. You can purchase an AC welding machine

for under $300 at most home improvement stores. There are three types of stick

welding machines: AC, DC, and AC/DC. As mentioned, the AC welder is going

to be the most economical and is ideal for metals thicker than 1/16th of an inch.

The DC welders are more expensive, but they also produce cleaner welds and

are more versatile when it comes to working with thinner metals.

Stick - Shielded Metal Arc Welding (SMAW) Shielded Metal Arc

Welding Commonly referred to as Stick, the shielded metal arc welding is a

process that uses an electrode to carry electric current in order to be able to

provide most of the weld metal. The electrode used for this method consists of a

core wire that is coded influx and the electric arc is created when the tip of the

electrode that is the work piece and is withdrawn while still remaining in close

contact in order to generate temperatures of about 6500°F. The molten metal is

protected from nitrates and oxides in the atmosphere during this process, which

means that this process is a suitable one for pipeline welding, construction,

heavy equipment repair, and steel erection. The main advantages of using the

shielded metal arc welding technique include the low cost of the equipment that

is necessary, as well as its portability. There is no need for shielding gas as in

the TIG or MIG welding techniques, which means that you can use this technique
 15

outside even during wind or rain. Moreover, this technique also works on dirty

and rusty metals so it is a suitable alternative for those projects where you can

simply not use the TIG or MIG techniques. On the other hand, the disadvantages

of the shielded metal arc welding technique include the lower consumable

efficiency, as the quite a lot of waste is produced by welding in this way, and the

high operator skill required. It is actually quite going to take you a bit longer than

other methods to master the required skills, considering the fact that the method

is also rather difficult to use on thin materials. This method is usually considered

obsolete when compared to the MIG anti-ageing methods mostly because it is

primarily a manual welding technique. However, the process is sometimes

necessary because it is not always possible to use TIG or MIG welding due to

the position, type of material, and skill. This type of welding offers a very low cost

solution that does not require much expensive equipment. As a result, the quality

of the final weld may not be the best possible, mostly because this technique

may allow for shallow penetration, porosity, cracking, and a vulnerability to

severe weather. (http://welderstation.com/different-types-of-welding-processes/)

According to Vinodh Reddy Chennu (2015) there are five different

types of welded joints for bringing two parts together for joining. Five types of

welded joints are butt joint, corner joint, lap joint, tee-joint and edge joint.1. Butt

joint: In Butt welded type; the parts lie in the same plane and are joined at their

edges. 2. Corner joint: The parts in a corner joint form a right angle and are

joined at the center of the angle. 3. Lap joint: Lap joint consists of two

overlapping parts. Butt joint, corner joint, lap joint, T joint and edge joint4. Tee-
 16

joint: In a Tee-joint, one joint is the right angle to the other joint in the

approximate shape of the letter “T”. 5. Edge joint: The parts in edge joint are

parallel with at least one of their edges in common and the joint is made at the

common edges.

According to Mike Aguilar / Mechanical Engineering welding is the

process by which two pieces of metal can be joined together. The process of

welding doesn't merely bond the two pieces together as in brazing and soldering,

but, through the use of extreme heat and sometimes the addition of other metals

or gases, causes the metallic structures of the two pieces to join together and

become one. There are a number of different welding methods, including spot

welding, metal inert gas (MIG), and tungsten inert gas, which are forms of gas

metal arc welding, arc welding, and gas welding, to name a few. Welding can

even be done underwater. The type of joint to be created and the type of material

to be used, among other considerations, will determine the type of welding

process that will be used to complete the project. All welding processes can be

broken down into the two following categories: Pressure welding is a process in

which external pressure is applied to produce welded joints either at

temperatures below the melting point, which is solid state welding, or at a

temperature above the melting point, which is fusion state welding. The atoms

are moved together to a distance that is equal to or less than the equilibrium inter

atomic separation distance. This type of welding process requires the two pieces

being joined to be extremely clean and especially free of oxides and non-metallic

films which must be removed from the surfaces of the metals by wire brush, so
 17

as to ensure the strongest welded joint possible. Pressure welding techniques

are used primarily on metals that are highly ductile or whose ductility increases

with increasing temperatures. Types of commonly used pressure welding

processes in industrial applications are: Cold pressure welding is used for joining

sheets, wires and electric components. Explosive welding is used when joints of

dissimilar metals are to be welded. Ultrasonic welding, when thin sheets are to

be joined. Percussion welding is utilized for joining dissimilar metals. Friction

welding is used when similar or dissimilar metals are to be joined. Induction

welding is used for welding pipes Inertial welding is for welding of high strength

alloys. (https://www.brighthubengineering.com/manufacturing-technology/30578-

types-of-welding-processes/)

According to Mike Allen write on (December 12, 2008) to in his article

the title is "Master Basic Welding Skills a step - by - step Guide. Say welding is a

delicate art but once you learn it; ordinary steel becomes a blank canvas for

invention. Whatever the think in your mind is the specific respond undertake on

welding. Because if say competence it’s a feature that commutates. The level

practical skills to ask yourself what I have learned to determine the competence.

If it increases to decrease acknowledge on step by step welding process.

According to Oanh Nguyen (August 5, 2014) in this article while that “An

Introduction to SMAW Shielding Metal Arc Welding ". It said for statement with a

seven-month professional welder program you can avert a higher yearly income

than average. If you are a welder beginner or amateur, you have to do take a lot

of time or spend a lot a time to pursuing practice and make of recognize them
 18

and learn from because failure is normal it is either you quit or learn from it.

Become faithful in your work.

According to this article by Nariendra Singh (July 24, 2017,)The

welders can upgrade their skills so that they can become readily employable

from manual to mechanized welding " Developing the skills in welding " like

example don’t say no have for this you should say this not my priority and this is

my important to me because if the welder is want to become certified welder you

partake I laboratory respondent to their in this to learn from this and experience

from them the best recommendation is become. Persistent patient uncomplaining

what have been through feel in your works article?

According to Wikipedia Fillet welding refers to the process of joining

two pieces of metal together whether they are perpendicular or at an angle.

These welds are commonly referred to as Tee joints which are two pieces of

metal perpendicular to each other there are 5 pieces to each Fillet weld known as
 19

the Root, Toe, Face, Leg and Throat. The root of the weld is the part of deepest

penetration which is the opposite angle of the hypotenuse. The toes of the weld

are essentially the edges or the points of the hypotenuse. The face of the weld is

the outer visual or hypotenuse that you see when looking at a fillet weld. The legs

are the opposite and adjacent sides to the triangular fillet weld. The leg length is

usually designated as the size of the weld. The throat of the weld is the distance

from the center of the face to the root of the weld. Typically, the depth of the

throat should be at least as thick as the thickness of metal you are welding.

https://en.wikipedia.org/wiki/Fillet_weld

https://commons.wikimedia.org/w/index.php?curid=25942071

According to this website entitled the “Four Basic Welding Positions”

are: flat, horizontal, vertical, and overhead. The most common type of weld you

will do is a Fillet weld and a Groove weld, and you can accomplish these welds in

all four positions. But you also do surface welds in all four positions as well,

thought you will not do this type of weld very often. There are numbers that are

used to designate the type of welding position and weld.

https://www.wcwelding.com/welding-positions.html
 20

https://www.wcwelding.com/images/xfillet-welding-

positions.jpg.pagespeed.ic.BZB_ec2JY3.jpg

According to this website 5 essentials for proper welding procedures

besides the steady sizzling sound that a correct arc produces, the shape of the

molten pool and the movement of the metal at the rear of the pool serve as a

guide in checking weld quality. In a correctly made deposit the ripples produced

on the bead will be uniform and the bead will be smooth, with no overlap or

undercut. Correct electrode size the correct choice of electrode size involves

consideration of a variety of factors, such as the type, position, and preparation

of the joint, the ability of the electrode to carry high current values without injury

to the weld metal or loss of deposition efficiency, the mass of work metal and its

ability to maintain its original properties after welding, the characteristics of the

assembly with reference to effect of stresses set up by heat application, the

practicability of heat treatment before and/or after welding, the specific

requirements as to welding quality and the cost of achieving the desired results.

Correct current if current on equipment is too high or too low, you are certain to

be disappointed in your weld. If too high, the electrode melts too fast and your
 21

molten pool is large and irregular. If too low, there is not enough heat to melt the

base metal and your molten pool will be too small, will pile up, and look irregular.

Correct arc length or voltage if the arc is too long or voltage too high the metal

melts off the electrode in large globules which wobble from side to side as the arc

wavers, giving a wide, spattered and irregular bead-with poor fusion between

original metal and deposited metal. If arc is too short, or voltage too low, there is

not enough heat to melt the base metal properly and the electrode quite often

stick to the work, giving a high, uneven bead, having irregular ripples with poor

fusion. Correct travel speed when your speed is too fast your pool does not last

long enough, impurities and gas are locked in. the bead is narrow and ripples

pointed. When speed is too slow the metal piles up, the bead is high and wide,

with a rather straight ripple. Correct electrode angle the electrode angle is of

particular importance in fillet welding and deep groove welding.

http://www.jainwelding.com/index.php?

option=com_content&view=article&id=6...#a
 22

https://ww

w.welding.org/wp-content/uploads/2014/09/236_6_.jpg

According to this article by Bill West (January 25, 2008) its talk about

“5 tips to get it right when it's needed most” Choose the right electrode fighting

gravity is the main challenge in vertical-up welding—or any position that is 45

degrees or steeper. Stick electrodes with an AWS classification of 7018 are

considered the first choice because of their low iron powder content. Create a

weld shelf of the five welding positions—flat, horizontal, overhead, vertical-up,

and vertical-down—vertical-up is the slowest because the welder needs to

combat gravity. Avoid undercutting one error to avoid while weaving is

undercutting. This occurs when the work is gouged without sufficient filler metal,

as gravity draws the filler metal away from the work. Use a low power setting

because a vertical-up puddle needs to freeze quickly and in place, a low

amperage setting is needed to maintain control. Welding in the flat position

carries the benefit of gravity and can be performed at lower temperatures and
 23

faster travel speeds. Consider flux-cored vertical-up welding flux-cored welding

has replaced some of the traditional stick welding in many construction markets

because of its higher productivity resulting from a continuously fed wire.

However, many ironworkers prefer stick, which can be more convenient.

https://www.thefabricator.com/thefabricator/article/arcwelding/vertical-smaw-its-a-

stick-up

According to this article by Dwight Myers and Jay Ginder (August

29, 2016) “5 things you need to know about modern stick welding” Shielded

metal arc welding still plays an important role in metal fabricating The power

source used for industrial SMAW is very different from a small buzz box available

at the nearby big-box store. If you are involved in SMAW, you are going to be

using a constant-current machine. Odds are, however, that the machine is going

to be capable of a whole lot more. Modern power sources have technological

enhancements aimed at helping stick welders. SMAW power sources don’t grab

the headlines with frequent technology advancements like those associated with

gas metal arc welding, but that doesn’t mean that today’s power sources are the

same as boxes from 25 years ago. Today’s electrodes are more moisture-

resistant when compared to electrodes used 10 years ago. Hydrogen cracking

used to be a real concern for stick welders. Earlier generations of electrodes

released hydrogen at a greater rate than those of today, which contributed to

cracking at the joint at a later time. Cracks in ship hulls were a particular problem

in the middle of the 20th century. Electrodes are tailored to special applications. It

seems like stick welders today might be able to find an electrode for almost any
 24

application. Do they need an electrode for military applications where the joint

has to demonstrate greater yield strengths than typical welds? Are they working

on projects where the work piece will be stress-relieved for as many as 24

hours? Do they require a special electrode that is compatible with alloys used in

some pressure vessel fabrications and has to demonstrate good impact

resistance and stand up to low temperatures? There are electrodes for all of

those applications. SMAW still requires skill. SMAW equipment and electrodes

may be more user-friendly, but a person still needs to have some skills to be an

effective stick welder. Consider a welder using a 6010 electrode in a general

repair scenario. The electrode is very aggressive and runs very hot. A welder

needs to keep the arc-to-metal distance pretty consistent, because if he creates

an arc that is too long, pop-outs can occur. (Pop-outs are when voltage drops,

which is the result of an electrode being too far from the base metal.) Pop-outs

can create weld defects. The goal is to create a complete weld with no stops and,

of course, no pop-outs. That requires a consistent weld movement.

https://www.thefabricator.com/thefabricator/article/arcwelding/5-things-you-need-

to-know-about-modern-stick-welding
 25

https://cdn.thefabricator.com/a/5-things-you-need-to-know-about-modern-stick-welding-

1.jpg?size=1000x

According to this article by Michael Allen and Nathan Lott (July 17, 2017)

“Stick electrode and welding basics everything you need to know about shielded

metal arc welding” Oscar Kjellberg invented the world’s first coated welding

electrode in 1904 by dipping a bare wire into a mixture of carbonates (including

wood pulp, or cellulose) and silicates to act as a binder. While advances in

metallurgy, electrode coating composition, and manufacturing techniques

continue to this day, the fundamental principles of shielded metal arc welding

(SMAW), also commonly known as stick welding, remain. The electrode coating

provides: Arc shielding when the calcium carbonate (CACO3) in the coating

decomposes to CAO and CO2 under arc heat. The primary source of the slag

system, which supports the weld puddle and helps remove impurities from the

molten metal weld deposit. Arc stability through elements such as sodium and

potassium. A primary source of alloying and additional filler metal. Just because
 26

a process is old doesn’t mean it’s not relevant. SMAW electrodes account for

about 20 percent of the filler metal market. The quantity of electrodes consumed,

estimated at about 150 million to 200 million pounds in North America, split

between low-hydrogen and other types, and has remained relatively constant for

the last five years. This consistent demand for SMAW electrodes supports the

premise that every application has a welding process that works best, and when

to come to situations that require portability and simplicity, SMAW offers the most

benefits, which are summarized.

https://www.thefabricator.com/thefabricator/article/arcwelding/stick-electrode-and-welding-

basics

According to this website entitle “4 Common Weld Defects & How to

Prevent Them in Your Sheet Metal Design” Let us translate: Porosity = gas

bubbles. Porosity occurs when shielding gas becomes trapped within the weld

and releases through the weld after it hardens. The release of the gas leaves tiny

holes in the weld. Porosity is especially destructive in metal inert gas (MIG) or

stick welds. Consequences of weld porosity: Cracks both visible and internal

weakened weld joints How to prevent weld porosity: If using multiple metal types,

make sure you’re specifying similar ones. Have a certified welding inspector use

X-rays and ultrasound to check for holes. Overlap is an excess of weld metal

beyond the weld root. This is a type of weld discontinuity, not necessarily a weld

defect. Weld overlap frequently occurs with fillet or butt welds (common weld

types in metal fabrication). This may be due to insufficient heat application.

Consequences of weld overlap: Little to no fusion of the pieces Concentrated

 27

stress under load How to prevent weld overlap: Use a metal type and grade more

agreeable with high-heat conditions. Distortion can result when the parent metal

being welded on warps due to excessive heat created by the welding process.

This usually occurs on thinner gauge sheet metals as they lack the surface area

to dissipate the heat. It also can occur when creating longer welds, due to there

being an extended length of time when the metal is exposed to heat.

Consequences of weld distortion: Warped metal isn’t structurally sound How to

prevent weld distortion: Avoid stainless steel, since it’s especially prone to

shifting position during a weld Use a more wieldable metal type and grade so

less passes are necessary Stop specifying so many welds! Find a more skilled,

experienced welder. This occurs when the parent metal and the weld metal do

not completely adhere to each other. Lack of penetration occurs when a weld

does not begin at the root of the weld groove. These usually occur due to poor

welding technique -- perhaps an incorrect angle, excessive speed, or insufficient

arc length. Consequences of a lack of weld fusion: Connection won’t be solid or

long-lasting How to prevent a lack of weld fusion: Find a more skilled,

experienced welder Use a thinner piece of metal.

 28

Distortion

https://blog.blackadvtech.com/common-weld-defects-how-to-prevent

Porosity

https://blog.blackadvtech.com/hubfs/weld%20defects%202.jpg
 29

Lack of Fusion

https://blog.blackadvtech.com/common-weld-defects-how-to-prevent
 30

Lack of Overlap

https://blog.blackadvtech.com/hubfs/weld%20defects%204.jpg
 31

SYNTHESIS OF STUDY

The review of related literature discusses that practical skills of SMAW is

have many ways how to improve the skills in SMAW actual competence. The

source 1 talks about how to weld procedure or process is intended to teach you

how to use a flux cored arc welder. This machine is one of the most basic

welders available on the market today and is known for being both user-friendly

and cost-efficient. Although there are several limitations as to what you can get

away with on this machine, it is a great welder for beginners and is perfect for

doing non-structural, ornamental welding. The source 2 talks about as a

refresher, welding are the process of joining two or more metal parts by melting

the pieces and adding filler material. The filler is melted and pools between the

other pieces. The end result after the materials cool is a strong joint or weld.

When it comes to traditional welding techniques, there are three basic types. The

source 3 talks about Stick - Shielded Metal Arc Welding (SMAW) Shielded Metal

Arc Welding Commonly referred to as Stick, the shielded metal arc welding is a

process that uses an electrode to carry electric current in order to be able to

provide most of the weld metal. The source 4 talks about there are five different

types of welded joints for bringing two parts together for joining. Five types of

welded joints are butt joint, corner joint, and lap joint, tee-joint and edge joint. The

source 5 talks about. The process of welding doesn't merely bond the two pieces

together as in brazing and soldering, but, through the use of extreme heat and

sometimes the addition of other metals or gases, causes the metallic structures
 32

of the two pieces to join together and become one. The source 6 talks about

"Master Basic Welding Skills a step - by - step Guide. Say welding is a delicate

art but once you learn it; ordinary steel becomes a blank canvas for invention.

Whatever the think in your mind is the specific respond undertake on welding.

The source 7 talks about it said for statement with a seven-month professional

welder program you can avert a higher yearly income than average. If you are a

welder beginner or amateur, you have to do take a lot of time or spend a lot a

time to pursuing practice and make of recognize them and learn from because

failure is normal it is either you quit or learn from it. Become faithful in your work.

The source 8 talks about The welders can upgrade their skills so that they can

become readily employable from manual to mechanized welding " Developing

the skills in welding " like example don’t say no have for this you should say this

not my priority and this is my important to me because if the welder is want to

become certified welder you partake. The source 9 talks about these welds are

commonly referred to as Tee joints which are two pieces of metal perpendicular

to each other. There are 5 pieces to each Fillet weld known as the Root, Toe,

Face, Leg and Throat. The root of the weld is the part of deepest penetration

which is the opposite angle of the hypotenuse. The source 10 talks about “Four

Basic Welding Positions” are: flat, horizontal, vertical, and overhead. The most

common type of weld you will do is a Fillet weld and a Groove weld, and you can

accomplish these welds in all four positions. The source 11 talks about 5

essentials for proper welding procedures besides the steady sizzling sound that a

correct arc produces, the shape of the molten pool and the movement of the
 33

metal at the rear of the pool serve as a guide in checking weld quality. In a

correctly made deposit the ripples produced on the bead will be uniform and the

bead will be smooth, with no overlap or undercut. The source 12 talks about “5

tips to get it right when it's needed most” Choose the right electrode fighting

gravity is the main challenge in vertical-up welding—or any position that is 45

degrees or steeper. Stick electrodes with an AWS classification of 7018 are

considered the first choice because of their low iron powder content. Create a

weld shelf of the five welding positions—flat, horizontal, overhead, vertical-up,

and vertical-down. The source 13 talks about “5 things you need to know about

modern stick welding” Shielded metal arc welding still plays an important role in

metal fabricating The power source used for industrial SMAW is very different

from a small buzz box available at the nearby big-box store. If you are involved in

SMAW, you are going to be using a constant-current machine. Odds are,

however, that the machine is going to be capable of a whole lot more. Modern

power sources have technological enhancements aimed at helping stick welders.

The source 14 talks about Stick electrode and welding basics everything you

need to know about shielded metal arc welding” Oscar Kjellberg invented the

world’s first coated welding electrode in 1904 by dipping a bare wire into a

mixture of carbonates (including wood pulp, or cellulose) and silicates to act as a

binder. While advances in metallurgy, electrode coating composition, and

manufacturing techniques continue to this day, the fundamental principles of

shielded metal arc welding (SMAW), also commonly known as stick welding,

remain. The source 15 talks about “4 Common Weld Defects & How to Prevent
 34

Them in Your Sheet Metal Design” Let us translate: Porosity = gas bubbles.

Porosity occurs when shielding gas becomes trapped within the weld and

releases through the weld after it hardens. The release of the gas leaves tiny

holes in the weld. Porosity is especially destructive in metal inert gas (MIG) or

stick welds. Consequences of weld porosity: Cracks both visible and internal

weakened weld joints How to prevent weld porosity.

CHAPTER 3
 35

METHODOLOGY

This chapter discuss of the research design, data collection technique,

respondent of the study, sampling technique and data analysis. This Study will

focus the level of practical skills in SMAW grade 11 IA-welding student purposed

an intervention program.

RESEARCH DESIGN

The researchers use the descriptive research design in a form of likers scale

because it defined as the process of conducting research using surveys that are

sent to survey respondents. The data collected from surveys is then statistically

analyzed to draw meaningful research conclusions. It shows is a quantitative

method whereby a researcher poses some set of predetermined questions of

individuals. Survey research is an especially useful approach when a researcher

aims to identify or determine the level of practical skills in SMAW subject among

IA welding student.

DATA COLLECTION TECHNIQUE

The technique in data collection is order to gather information from every

participant give questionnaire from grade 11 IA-SMAW student 19 out of 27 or

70% of population as sample. An instrument is used consists a set of questions

or other types of prompts that aims to collect information from a respondent.

Questionnaires provide a relatively cheap, quick and efficient way of obtaining

amounts of information from a sample.

 36

RESPONDENT OF THE STUDY

The respondent of this study in Buting Senior High School population and

the sample is grade 11 IA-SMAW students. Where they are the only strand who

has the Subject in SMAW. The researcher will choose who among the students

can worthy recompense basis for an intervention program. Those persons who

have been invited to participate in a particular study and have actually taken part

in the study. In designing the sample, the researcher focuses on potential

respondents who have some level of familiarity with the phenomenon under

investigation.

SAMPLING TECHNIQUE

The researchers used random sampling population of Buting Senior High

School as the location where the researchers execute the gathering of

information on level of practical skills subject in SMAW. The sample population

answered the questionnaire; consist of 19 students from grade 11 currently

enrolled and practicing the competencies stated on the questionnaire. The

researchers used random sampling by selecting a group of student as sample for

the study. Each individual is chosen entirely by chance and each member of the

population has an equal chance of being included in the sample.

DATA ANALYSIS
 37

The researchers will gather the data needed by giving the survey

questionnaires to IA-SMAW Students of grade 11. They are the one who can

accurately give the information needed that will actively cooperate to our

research study. The researchers will let them to answer our survey questionnaire

that the researchers will do is the distribution of the survey questionnaire to the

grade 11 IA-SMAW students in Buting Senior High Schools each of the students

will have to answer every number given in the questionnaire by putting a check

sign in each of the box if they think they know and experience when performing

the practical skills of SMAW subject.

STATISTICAL TREATMENT OF DATA

Responses to the questionnaire by grade11 senior high school students were

statistically analyzed with the data requirements of the study. Students were

statistically analyzed with the data instruments of the study. To interpret the

percentage of practical skills subject in SMAW among grade 11 IA welding

student, the researcher will employ the following statistical treatment. The

tabulate analyze and prepare a graph in Microsoft excel form of likert scale is the

tools use to interpret data.

CHAPTER 4

PRESENTATION, ANALYSIS AND INTERPRETATION OF DATA

 38

This chapter presents the presenting, analyzing and interpreting data to know the

prior to welding if it is always, often, sometimes, rarely, never and to the practical

skills if it is highly competent, moderately competent, competent, low competent

and not competent. That show Graphs were used for data presentation to give

the overall view of the findings and to establish the practical skills in SMAW

subject among IA welding student.

11%
5% Highly Competent (%)
Moderately Competent(%)
Competent (%)
Low Competent(%)
Not Competent (%)
84%

Chart 1

Showing the competency in wearing Personal Protective Equipment

Out of 19 respondents from the grade 11 IA-SMAW student, 84% were

from get answer highly competent, 5% were from get answer moderately

competent, 11% were from get answer competent, 0% was from get answer low

competent, and 0% was from get answer not competent. Some of our

respondents from Grade 11 IA-SMAW student show the competency in wearing

personal protective equipment.

 39

32%
Highly Competent (%)
Moderately Competent (%)
Competent (%)
Low Competent (%)
Not COMPETENT (%)
68%

Chart 2

Showing the competency of cutting the steel plate before to the welding
start

Out of 19 respondents from the grade 11 IA-SMAW student, 77% were

from get answer competent, 23% were from get answer moderately competent,

0% was from get answer highly competent, 0% was from get answer low

competent, and 0% was from get answer not competent. Most of our

respondents are from Grade 11 IA-SMAW student that show their competency of

cutting the steel plate before welding start.

 40

Chart 3

Showing the competency of tacking side by side of the steel plate

Out of 19 respondents from the grade 11 IA-SMAW student, 68% were

from get answer highly competent, 32% were from get answer moderately

competent, 0% was from get answer competent, 0% was from get answer low

competent, and 0% was from get answer not competent. Most of our

respondents are from Grade 11 IA-SMAW student that show their competency of

tacking side by side of the steel plate.

5%
26%
26% Highly Competent (%)
Moderately Competent (%)
Competent (%)
Low Competent (%)
Not Competent (%)

42%
 41

11%

Highly Competent(%)
21% Moderately Competent(%)
Competent(%)
53%
Low Competent(%)
Not Competent(%)

16%

Chart 4

Showing the competency of grinding steel plate if your work is wrong

Out of 19 respondents from the grade 11 IA-SMAW student, 42% were

from get answer moderately competent, 26% were from get answer competent,

5% were from get answer low competent, 27% were from get answer highly

competent, and 0% was from get answer not competent. Most of our

respondents are from Grade 11 IA-SMAW student that show their competency in

grinding steel plate.

 42

18%

Highly Competent(%)
41%
Moderately Competent(%)
Competent(%)
Low Competent(%)
Not Competent(%)

41%

Chart 1

Practical Skills 1f (Flat Position)

As shown in the graph, that 53% says that highly competent, while the other

16% says that moderately competent, 21% says that competent, 10% says that

low competent, and the other 0% say that not competent. In this graph shows

that the respondents rate has majority in highly competent and the lowest rate is

not competent.

Chart 2

Practical Skills 2f (Horizontal Position)

 43

20%

40% Highly Competent(%)

Moderately Competent(%)
Competent(%)
Low Competent(%)
Not Competent(%)

40%

As shown in the graph, that 41% says that highly competent, while the

moderately competent is 41% were the same, 18% says that competent, 0%

says that low competent, and the other 0% say that not competent. In this graph

shows that the respondents rating in 2f position has the same percentage/rate in

highly competent and moderately competent but in lowest rate also has the same

rate the low competent and not competent.

Chart 3

Practical Skills 3f (Vertical Position)

As shown in the graph, 40% of two competent the highly competent and

the moderately competent were the same rate, 20% says that competent, 0%

says that low competent, and the other 0% say that not competent. In this graph
 44

17%

Highly Competent(%)
42% Moderately Competent(%)
Competent(%)
25% Low Competent(%)
Not Competent(%)

17%

shows that the respondents rating in 3f position has the same percentage/rate in

highly competent and moderately competent but in lowest rate also has the same

rate the low competent and not competent.

Chart 4

Practical Skills 4f (Overhead Position)

As shown in the graph,42% says that highly competent, 0% says that

moderately competent,16% says that competent, 25% says that low competent,

and the other 17% says that not competent. In this graph shows that the highest

rate is the highly competent and the lowest rate were the moderately competent.
 45

CHAPTER 5

SUMMARY, CONCLUSION AND RECOMMENDATION

This chapter contains the summary, conclusions and recommendations

of the whole study. The summary explains the brief of study which is would be

seen the important details much better clarify information. Generalization and

interference would be seen in conclusion while the recommendation discusses

the suggestion or advice to improve the negative findings. Generally, this chapter

aims to cover up the end result of the study.

Summary

This study was conducted for the purposed of determining the level of

practical skills subject in SMAW among grade 11 IA welding students and to

measure the competencies wherein highly competent, moderately competent,

competent, low competent and not competent. Some of them will answer a

questionnaire 19 students out of 27 students and 70% respondents of grade 11

IA welding students. The descriptive method is used of research was utilized and

the survey technique was used for gathering data. The questionnaire served as

the instrument for collecting data. Prior of welding, chart 1 shows that 84% highly
 46

competent, 5% moderately competent, 11% competent and the rest is 0%. Chart

2 shows that 77% competent, 23% moderately competent and the rest is 0%.

Chart 3 shows that 68% highly competent, 32% moderately competent and the

rest 0%. Chart 4 shows that 42% moderately competent, 26% competent, 27%

highly competent, 5% low competent and the rest 0%. Competencies on welding

chart 1 show that 53% highly competent, 21% competent, 16% moderately

competent, 10% low competent and 0% not competent. Charts 2 show that 41%

highly and moderately competent, 18% competent, and the rest 0%. Chart 3

shows that 40% highly and moderately competent, 20% competent and the rest

0%. Chart 4 show that 42% highly competent, 25% low competent, 17% not

competent, 16% competent and 0% moderately competent the data was

collecting in a form of pie graph used Microsoft excel .

Conclusion

The Prior of welding:

 Chart 1 Most of the respondent grade 11 welder student’s highly

competent wear personal protective equipment but some respondent not

fully highly competent before start to used welding laboratory.

 Chart 2 Grade 11 IA-SMAW students in 19 respondents were get the

highest percentage is competent of cutting the steel plate before to the

welding start.
 47

 Chart 3 Respondents more highly competent than moderately competent,

low competent, competent and not competent of tacking side by side of

steel plate.

 Chart 4 Some of respondents answer our survey questionnaire is

moderately competent is the highest and the next is competent and highly

competent should perform grinding when welder students encounter

mistake in welding processing.

The practical skills:

 Chart 1 The practical skills in 1f flat position is easily to perform than 2f

horizontal position, 3f vertical position and 4f overhead position because

this is the highest frequency according to the pie chart percentage.

 Chart 2 The practical skills in 2f horizontal position got the same

percentage in highly and moderately competent which is the third easily

from respondent grade 11 IA-SMAW.

 Chart 3 the practical skills in 3f vertical position got the same percentage

in highly and moderately competent is most difficult than other practical

skills presenting the pie chart percentage.

 Chart 4 The practical skills in 4f overhead position is the second easily to

perform in terms of welding processing it’s all about during welding

laboratory time.
 48

Recommendation:

1. Safety Measure (Personal Protective and Equipment)

-Continuous budget for personal protective and equipment materials

-Buddy system checking strategy

2.1 Cutting of plates

2.2 Tacking

2.3 Grinding

-Continuous Budget for Hand Tools

-Provide user manual of quick card for different hand tools.

3. 1f / 2f / 3f / 4f Welding Positions

3.1 More activity on welding manipulation (Pen & Paper Practice)

3.2 Comprehensive training guide that will cover a skills for grade 11 SMAW.
 49

3.2 (a)-Appropriate training duration the SMAW practical appropriate (TESDA &

DEPED approach).

3.2 (b)-Identify approaches on the applying basic principle of 5 essential of

welding.

Reference
50