Competency-Based Learning Materials

Facilitating Learning
Sessions
 HOW TO USE THIS COMPETENCY BASED LEARNING
MATERIALS

Welcome to the module in Perform Root Pass. This module contains training
materials and activities for you to complete.
The unit of competency "Perform Root Pass" contains knowledge, skills and
attitudes required for Shielded Metal Arc Welding NCII.
You are required to go through a series of learning activities in order to complete
each learning outcome of the module. Information Sheets consists of learning contents
that you need to learn. Each Information sheet has a learning objective that you need to
attain while reading the Information Sheets. After each Information Sheet is a Self-
Check that will help you test yourself if you have attained the learning objectives.
Task Sheets and Job Sheets are activity sheets that will help you practice the skills
previously discussed in the Information Sheets or demonstrated by your trainer. A
Performance Criteria Checklist is provided with the Task Sheets and Job Sheets which
will allow for self-evaluation or peer evaluation. This Performance Criteria may be used
by your trainer to evaluate your performance. Follow these activities on your own. If you
have questions, don’t hesitate to ask your trainer for assistance.
The goal of this course is the development of practical skills. To gain these skills,
you must learn basic concepts and terminology. For the most part, you'll get this
information from the Information Sheets and TESDA Website, www.tesda.gov.ph
This module was prepared to help you achieve the required competency, in "Facilitating
Learning Sessions".
This will be the source of information for you to acquire knowledge and skills in
this particular competency independently and at your own pace, with minimum
supervision or help from your instructor.

Remember to:
 Work through all the information and complete the activities in each section.
 Read information sheets and complete the self-check. Suggested references are
included to supplement the materials provided in this module.
 Perform the Task Sheets and Job Sheets until you are confident that your
outputs conform to the Performance Criteria Checklist that follows the sheets.
 Submit outputs of the Task Sheets and Job Sheets to your facilitator for
evaluation and recording in the Accomplishment Chart. Outputs shall serve as
your portfolio during the Institutional Competency Evaluation. When you feel
confident that you have had sufficient practice, ask your Trainer to evaluate you.
The results of your assessment will be recorded in your Progress Chart and
Accomplishment Chart.

You must pass the Institutional Competency Evaluation for this competency
before moving to another competency. A Certificate of Achievement will be awarded to
you after passing the evaluation.

CBLMs on Trainers Date Developed: Document No.

Issued by:
Methodology I
Date Revised: Page i of x
Facilitating Learning
Developed by:
Sessions Revision # 0
CBLMs on Trainers Date Developed: Document No.
Issued by:
Methodology I
Date Revised: Page ii of x
Facilitating Learning
Developed by:
Sessions Revision # 01
 SHIELDED METAL ARC WELDING NC II
COMPETENCY-BASED LEARNING MATERIALS

List of Competencies

No. Unit of Competency Module Title Code

1.
2.
3.
4.

CBLMs on Trainers Date Developed: Document No.

Issued by:
Methodology I
Date Revised: Page iii of x
Facilitating Learning
Developed by:
Sessions Revision # 0
 Table of Contents

HOW TO USE THIS COMPETENCY BASED LEARNING MATERIAL..................................................... i

List of Competencies ....................................................................................................................iii

Table of Contents...........................................................................................................................v

MODULE CONTENT....................................................................................................................... vi

LEARNING OUTCOME #1 Prepare Training Facilities/Resources ................................................... 1

Learning Experiences ................................................................................................................... 3
Information Sheet 2.1-1 The Principles of Competency Based Training ....................................... 4
Self-Check 2.1-1 ........................................................................................................................... 7
Answer Key 2.1-1........................................................................................................................... 8
Information Sheet 2.1-2 Characteristics of CBT ........................................................................... 9
Self-Check 2.1-2 ..........................................................................................................................12
Answer Key 2.1-2.........................................................................................................................13
Information Sheet 2.1-3 Principles of Adult Learning .................................................................14
Self-Check 2.1-3 ..........................................................................................................................16
Answer Key 2.1-3..........................................................................................................................17
Information Sheet 2.1-4 Delivery Plans .......................................................................................18
Self-Check 2.1-4 ..........................................................................................................................24
Answer Key 2.1-4.........................................................................................................................25
Information Sheet 2.1-5 Learning Stations .................................................................................26
Self-Check 2.1-5 ..........................................................................................................................28
Answer Key 2.1-5.........................................................................................................................29
Information Sheet 2.1-6 Training Activity Matrix ........................................................................30
Self-Check 2.1-6 ..........................................................................................................................33
Answer Key 2.1-6..........................................................................................................................34
Task Sheet 2.1-6 Prepare Training Matrix ..................................................................................35
Performance Criteria Checklist 2.1-6...........................................................................................36

LEARNING OUTCOME #2 Conduct Pre-assessment ........................................................................37

Learning Experiences ..................................................................................................................38
Information Sheet 2.2-2 Recognition of Prior Learning ...............................................................39
Self-Check 2.2-1 ..........................................................................................................................42
Answer Key 2.2-1.........................................................................................................................43
Information Sheet 2.2-2 Pre-assessment ......................................................................................44
Self-check 2.2-2............................................................................................................................49
Answer Key 2.2-2..........................................................................................................................50
Job Sheet 2.2-2 Conduct Pre-assessment......................................................................................51
Performance Criteria Checklist 2.2-2...........................................................................................53

LEARNING OUTCOME #3 Facilitate Training Session ...................................................................54

Learning Experiences ..................................................................................................................56
Information Sheet 2.3-1 Competency Based Training Delivery ....................................................58
SELF-CHECK 2.3-1........................................................................................................................63

CBLMs on Trainers Date Developed: Document No.

July 2010 Issued by:
Methodology I Date Revised: Page iv of x
March 2012 NTTA
Facilitating Learning
Developed by:
Sessions Redilyn C. Agub Revision # 01
Answer Key 2.3-1..........................................................................................................................64
Job Sheet 2.3-1 Prepare a Demonstration-Performance Method Training Session .......................65
Information Sheet 2.3-2 Feedback Mechanism ............................................................................66
Self-Check 2.3-2 ..........................................................................................................................73
Answer Key 2.3-2..........................................................................................................................74
Information Sheet 2.3-3 CBT Monitoring Tools.............................................................................76
Answer Key 2.3-3..........................................................................................................................81
Task Sheet 2.3-3a Prepare Progress Chart...................................................................................82
Task Sheet 2.3-3b Prepare Achievement Chart.............................................................................84
Performance Criteria 2.3-3b.........................................................................................................85
Information Sheet 2.3-4 The Competency Based Training Procedures..........................................86
Self-Check 2.3-4 ..........................................................................................................................91
Self-Check 2.3-4 ..........................................................................................................................92
Job Sheet 2.3-4 Facilitate Training Session ................................................................................93
Performance Criteria Checklist 2.3-4...........................................................................................94
Information Sheet 2.3-5 Focused Group Discussion .....................................................................95
Self-Check 2.3-5 ........................................................................................................................101
Answer Key 2.3-5........................................................................................................................102
Job Sheet 2.3-5 Focused Group Discussion fo Facilitate Learning Session ................................105
Performance Criteria Checklist 2.3-5.........................................................................................106

LEARNING OUTCOME #4 Conduct Competency Assessment ........................................................107

Learning Experiences ................................................................................................................108
Information Sheet 2.4-1 Institutional Competency Evaluation ..................................................109
Job Sheet 2.4-1 Conduct Institutional Competency Evaluation ..................................................113
Performance Checklist 2.4-1 .....................................................................................................114

LEARNING OUTCOME #5 Review Delivery of Training Session.....................................................116

Learning Experiences ................................................................................................................117
Information Sheet 2.5-1 CBT Review and Evaluation.................................................................118
Self-Check 2.5-1 ........................................................................................................................123
Answer Key 2.5-1.......................................................................................................................124
Information Sheet 2.5-2 PRE-TEST POST-TEST Analysis ...........................................................125
Self-Check 2.5-2 ........................................................................................................................136
Answer Key 2.5-2.......................................................................................................................137
Task Sheet 2.5-2 Analyze pre-test/post test results ...................................................................138
Performance Criteria Checklist 2.5-2.........................................................................................139
Information Sheet 2.5-3 Training Evaluation Analysis .............................................................140
Self-Check 2.5-3 ........................................................................................................................150
Answer Key 2.5-3........................................................................................................................151
Job Sheet 2.5-3 Analyze Training Evaluation ............................................................................152
Performance Criteria Checklist 2.5-3.........................................................................................153
Information Sheet 2.5-4 Training Session Adjustment...............................................................154
Self-Check 2.5-4 ........................................................................................................................155
Answer Key 2.5-4........................................................................................................................156

CBLMs on Trainers Date Developed: Document No.

July 2010 Issued by:
Methodology I Date Revised: Page v of x
March 2012 NTTA
Facilitating Learning
Developed by:
Sessions Redilyn C. Agub Revision # 01
 MODULE CONTENT

Qualification Title : Shielded Metal Arc Welding (SMAW) NC II

Unit of Competency : Weld Carbon Steel Plates and Pipes Using SMAW
Module Title : Welding Carbon Steel

Introduction
This module covers the knowledge, skills and attitude in performing groove
welding on carbon steel plates in different positions such as 1G, 2G, 3G, & 4G.
This module covers groove welding on carbon steel pipe in different positions such
as 2G, 5G & 6G. This session covers the knowledge, skills and attitudes required
in welding carbon steel plates and pipes using SMAW process.

Learning Outcomes:
Upon completion of this module, you must be able to:
1. Perform root pass
2. Clean root pass
3. Weld subsequent/filling passes
4. Perform capping

Assessment Criteria:

1. Root penetration not exceeding allowable tolerances specified by welding

codes/ standards on
 concavity
 convexity
 undercut
 excess penetration
 lack of fusion
 burn-through
 cracks
2. Weld capping/ final pass not exceeding allowable tolerances specified by
welding codes/ standards on
 height of reinforcement
 under fill
 porosities
 undercut
 cracks
 cold laps
3. Uniformity of bead ripples must be in accordance with welding standards
4. Stringer or layered beads deposited in accordance with welding standards
5. Finish weldment visually acceptable in accordance with welding standards for:
 spatters
 arc strikes
 slag
 uniformity of beads
 LEARNING OUTCOME #1 PREPARE TRAINING FACILITIES/
RESOURCES
CONTENTS:
 Essentials of welding
 International welding codes and standards
 Acceptable weld profiles
 Weld defects, causes and remedies
 Welding Procedure Specifications (WPS)
 Welding techniques and procedures
 Safe welding practices
ASSESSMENT CRITERIA:
1. Root penetration not exceeding allowable tolerances
specified by welding codes/ standards on
 concavity
 convexity
 undercut
 excess penetration
 lack of fusion
 burn-through
 cracks
2. Weld capping/ final pass not exceeding allowable
tolerances specified by welding codes/ standards on
 height of reinforcement
 underfill
 porosities
 undercut
 cracks
 cold laps
3. Uniformity of bead ripples must be in accordance with
welding standards
4. Stringer or layered beads deposited in accordance with
welding standards
5. Finish weldment visually acceptable in accordance with
welding standards for:
 spatters
 arc strikes
 slag
 uniformity of beads
CONDITION:
The student/trainee must be provided with the following:
1. Equipment
- Welding machine (AC or AC/DC)
- Welding table or jig
- Portable grinder
 - Welding booth
- Portable oven

2. Tools/Accessories
- Welding mask
- Steel brush
- Clear glass
- Chipping hammer
- Dark glass
3. Supplies/ Materials
- Electrodes
- Carbon steel plates
- Cutting grinding disk
4. Personal protective equipment
- Safety shoes
- Apron
- Leggings
- Safety goggles
- Gloves
5. Training Materials
- Arc welding manuals
- Welding procedures specifications (WPS)
- Welding standards
ASSESSMENT METHOD:
Evaluation of Outputs(Portfolio)
Questioning
Written Test

Date Developed: Document No.

CBLMs on Trainers
July 2010 Issued by:
Methodology Level I Date Revised Page vii
vi of
ofviii
viii
March 2012 NTTA
Facilitating Training
Developed by:
Session Redilyn C. Agub Revision # 01
 Learning Experiences
Learning Outcome 1
Perform Root Pass

Learning Activities Special Instructions

1. Read Information Sheet Read and understand the information sheet
1.1-1 on essentials of and check yourself by answering the self-
welding check. You must answer all questions
2. Answer self-check correctly before proceeding to the next
questions 1.1-1 activity. You may check your answer by
3. Refer to answer key using the answer key.
1.1-1
 Information Sheet 1.1-1
Essentials of Welding

Learning Objectives:

At the end of this module, the trainee will be able to:

1. Recognize the Essentials of welding.
2. Illustrate the essentials of welding during the procedure.

Shielded metal arc welding (SMAW),

also known as manual metal arc
welding (MMA or MMAW), flux shielded
arc welding or informally as stick
welding, is a manual arc welding process
that uses a consumable electrode covered
with a flux to lay the weld.

An electric current, in the form of

either alternating current or direct
current from a welding power supply, is used to form an electric arc between
the electrode and the metals to be joined. The work piece and the electrode
melt forming a pool of molten metal (weld pool) that cools to form a joint. As
the weld is laid, the flux coating of the electrode disintegrates, giving off
vapours that serve as a shielding gas and providing a layer of slag, both of
which protect the weld area from atmospheric contamination.

Because of the versatility of the process and the simplicity of its

equipment and operation, shielded metal arc welding is one of the world's
first and most popular welding processes. It dominates other welding
processes in the maintenance and repair industry, and though flux-cored
arc welding is growing in popularity, SMAW continues to be used extensively
in the construction of heavy steel structures and in industrial fabrication.
The process is used primarily to weld iron and steels (including stainless
steel) but aluminium, nickel and copper alloys can also be welded with this
method.

5 ESSENTIALS OF SHIELDED METAL ARC WELDING

ELECTRODE SIZE
Electrodes for shielded metal arc welding range in diameter from 3/32
to 3/16 of an inch. You may also come across some ¼ inch electrodes. They
are commonly found in 9, 14 and 18-inch lengths.
Electrode diameter is based on the thickness of the base metal, the
welding position and the type of joint to be welded. Larger diameter
electrodes are used on thicker metals and for flat position welding because
they offer higher deposition rates.
Diameter of electrode in Electrodes
inches
3/32 40-80 45-90

1/8 75-125 80-130

5/32 110-170 105-180

3/16 140-215 150-230

Smaller diameter electrodes are used for horizontal, vertical and

overhead welding, because they produce a smaller weld puddle that is easier
to control than the bigger puddle produced by larger diameter electrodes.
Joint design also affects electrode diameter. On groove welds for example,
the electrode has to be small enough to access the root of the joint. he
welder’s skill also has a bearing on electrode diameter because a more
capable welder can control a larger, more fluid weld puddle.

As a general rule, when there is no welding procedure specification,

use the largest diameter electrode possible. Larger diameter electrodes
produce welds of the required dimensions in the least amount of time and at
lower cost, because they have higher deposition rates and allow faster travel
speeds.

CURRENT
Current is measured in amperes, or amps. Each type of electrode has
recommended amperage ranges for optimum performance. Amperage ranges
are usually specified in the welding procedure or in the manufacturers’ data
sheets.

If the amperage is set above the suggested operating range, the

electrode melts too fast. This increases deposition and the weld puddle
becomes too large to control. It could also cause the electrode coating to
overheat and break down.

Amperage too high – The weld bead is wide and flat with excessive
penetration and spatter, and undercutting frequently occurs along the toes.

If the amperage is set below the designated range, there is insufficient heat
to melt the base metal, and the weld puddle is too small for proper control.
The droplets forming on the end of the electrode may bridge to the weld
puddle periodically extinguishing the arc. The weld bead will be irregular
with a crowned appearance and insufficient penetration.

Amperage too low -The weld bead will be irregular with a crowned
appearance and insufficient penetration

Welding Current for Carbon Electrode Types

ARC LENGTH
Arc length is the distance from the tip of the electrode core wire to the
weld puddle. Arc length can be deceiving, because the core wire is recessed
inside a cup that forms at the tip of the electrode. You have to take this into
consideration when gauging arc length.

The correct arc length varies according to the

electrode classification, diameter and composition of
the flux coating, as well as the amperage and welding
position.

As a general rule, when amperage is set within

the specified range, arc length should not exceed the
diameter of the core wire. Increasing the arc length increases the arc
voltage, and reduces the amperage slightly.

If the arc is too long, the metal core melts off in large globules that
wobble from side to side and drop onto the work as spatter, rather than
forming useful weld metal. The weld bead is wide with excessive spatter and
undercut. The base metal is not properly melted, so the weld metal is
deposited on top of the plate with incomplete penetration, and slag
inclusions will probably occur. Long arcing is often used to preheat the base
metal directly after striking the arc.

Shortening the arc length reduces the arc voltage and increases the
amperage slightly. If the arc length is too short, the arc has a tendency to
short out and the electrode freezes to the work.

TRAVEL SPEED
Travel speed is the rate at which the electrode moves along the work.
The key to correct travel speed is “reading” the weld puddle, because the
weld puddle is a liquid version of the weld bead.

A properly formed weld bead has an oval shape with an oval crater
and uniform ripple pattern. Travel speed is influenced by the type of welding
current (DCEN, DCEP or AC), amperage, welding position, electrode melt
rate, material thickness, surface condition of the base metal, type of joint,
joint fit up and electrode manipulation.

If you travel too fast, the puddle cools too quickly trapping gasses and
slag. The ripples are pointed and narrow with irregular penetration and
undercut along the toes.

If you travel too slowly, the weld metal piles up forming a high, wide
weld-bead with too much reinforcement that may result in overlap. So read
the puddle, and keep the arc on the leading edge.

ELECTRODE ANGLE
In shielded metal arc welding, the work and travel angles are used to
control the shape of the weld puddle and the amount of penetration. The
travel angle is the angle between the joint and the electrode along the axis of
the weld.

A push angle exists when the electrode points in the direction of

travel. And a drag angle points away the direction of travel.

When all other essentials are under control, a change in the direction
of travel changes the heat input to the puddle. A drag travel angle increases
heat input because the arc is pointing into the puddle. A push travel angle
reduces heat input because the arc is pointing away from the puddle.

The work angle is pointing between the electrode and the work
surface along the work plane, which runs perpendicular to the axis of the
weld. An incorrect work angle can cause you to favour one side of the joint
more than another. The result is undercut and lack of fusion.
 Self-Check 1.1-1

Multiple Choices:
1. The following are the 5 essentials of welding except:
a. Electrode angle b. arc length c. module

2. Shielded Metal Arc Welding is also known as?

a. Manual Metal Arc Welding
b. Arc Welding
c. Gas Metal Arc Welding

3. The current is measure in?

a. Watts b. amperes c. volts

4. What do you called the cover coat of an electrode?

a. Fax b. flux c. flax

5. Essentials of welding are?

a. Electrode, electricity, arc length, electrode angle
b. Electrode size, current, arc length, travel speed, electrode angle
c. Travel charger, electric, watts, length, angle
 Answer Key 1.1-1
1. C
2. A
3. B
4. B
5. B
 Information Sheet 1.2-1
International Welding Codes and Standards