Tack Welding Instructor Guide

Instructor Guide Contents
Tack Welding
Instructor Guide
©
2012 Gulf State Shipbuilders Consortium
DISCLAIMER:
GSSC does not assume and hereby disclaims any liability to any party for any
loss or damage caused by any error or omission in this manual, whether such error
results from negligence, accident, or any other cause.
Tack Welding Instructor’s Guide Contents
Contents
Curriculum Overview ............................................................................... 1
Course Calendar ............................................................................. 2
Preparing to Teach .................................................................................. 3

Course Design ................................................................................ 4
Materials List ................................................................................... 5
Course Competencies..................................................................... 6
Instructor Introduction ..................................................................... 7
Tack Welding Answer Guide................................................................... 8

Course Introduction ......................................................................... 9
Presentation Activity—Course Benefits......................................... 10
Lesson 1 Introduction .................................................................... 11
Lesson 1—Tack Welding Safety ........................................................... 12

Lesson Overview........................................................................... 12
Lesson Learning Objectives .......................................................... 12
Lesson 1 – Part 1 .......................................................................... 13
Lab 1: Wearing Personal Protective Equipment ........................... 15
Lesson 1 – Part 2 .......................................................................... 17
Lab 2: SMAW Tack Welding ........................................................ 20
Quiz: Tack Welding Safety ........................................................... 21
PPE Application Assessment ........................................................ 24
Lesson 2—Tack Welding Basics .......................................................... 26

Lesson Overview........................................................................... 26
Lesson 2 – Part 1 .......................................................................... 27
Lab 3: Tack Welding Demonstration ............................................ 29
Lesson 2 – Part 2 .......................................................................... 30
Lab 4: Tack Weld Surface Preparation ........................................ 31
Lesson 2 – Part 3 .......................................................................... 32
Activity 3: AWS Welding Standards ............................................. 33
Lesson 2 – Part 4 .......................................................................... 34
Activity 4: Welding Position Designations .................................... 35
Lab 5: Welding Position Demonstration ....................................... 36
Lesson 2 – Part 5 .......................................................................... 37
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2012 Gulf States Shipbuilders Consortium ii
Lab 6: Structural Components..................................................... 40

Quiz: Tack Welding Basics .......................................................... 41
Lesson 3—Shielded Metal Arc Welding (SMAW) Equipment ............. 45

Lesson Overview........................................................................... 45
Lesson 3 – Part 1 .......................................................................... 46
Lesson 3 – Part 2 .......................................................................... 48
Lab 8: Hooking Up Welding Leads ............................................... 50
Lesson 3 – Part 3 .......................................................................... 51
Lab 9: Welding Machine Demonstration ...................................... 53
Lesson 3 – Part 4 .......................................................................... 54
Lab 10: Cable Connections and Stringing Cable.......................... 56
Lesson 3 – Part 5 .......................................................................... 57
Lab 11: Attaching a Ground Clamp .............................................. 59
Lesson 3 – Part 6 .......................................................................... 60
Lab 12: Using Hand Tools to Clean and Prepare Work Surfaces 62
Quiz: Shielded Metal Arc Welding (SMAW) Equipment ............... 63
Lesson 4—SMAW Electrodes ............................................................... 68

Lesson Overview........................................................................... 68
Lesson 4 – Part 1 .......................................................................... 69
Lab 13: Tack Welding Demonstration .......................................... 73
Activity 6: Testing for Base Metal and Electrode Compatibility
Demonstration ............................................................................... 75
Lab 14: Low-Hydrogen Electrode Demonstration......................... 76
Quiz: SMAW Electrodes ............................................................... 77
Lesson 5—SMAW Techniques ............................................................. 81

Lesson Overview........................................................................... 81
Lesson 5 – Part 1 .......................................................................... 82
Activity 7: Weld Coupons ............................................................. 84
Lesson 5 – Part 2 .......................................................................... 86
Lab 16: Setup of SMAW Equipment............................................. 87
Lesson 5 – Part 3 .......................................................................... 88
Lab 17: Striking an Arc ................................................................. 90
Lesson 5 – Part 4 .......................................................................... 91
Lab 18: Fillet and Groove Tack Welding Demonstration .............. 93
Lab 19: Good and Bad Tack Weld Demonstration ....................... 93
Lesson 5 – Part 5 .......................................................................... 95
Lab 20: Creating Tack Welds ....................................................... 96
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2012 Gulf States Shipbuilders Consortium iii
Quiz: SMAW Techniques ............................................................. 97

Summary and Assessment ......................................................... 100
Final Assessment: Tack Welding ............................................... 101
Tack Welding Application Assessment ....................................... 111
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2012 Gulf States Shipbuilders Consortium iv
Tack Welding Instructor’s Guide Curriculum Overview
Curriculum Overview
This Instructor Guide will help you with the following course:
1. Tack Welding
As you read through this Instructor Guide, you will find help with:
 Scheduling: A comprehensive schedule (ALL courses) is provided

 Organizational Structure: A framework for facilitating classroom training
 Materials: A list of materials required for the above course only
 Answer Guide: An Answer Guide to provide you with guidance and
answers for the activities and final assessments for the courses listed
above.
 Final Assessments: Knowledge and Application Assessments
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2012 Gulf States Shipbuilders Consortium 1
Tack Welding Instructor’s Guide Curriculum Overview
Course Calendar
WEEK #1 WEEK #2 WEEK #3 WEEK #4 WEEK #5 WEEK #6 WEEK #7 WEEK #8 WEEK #9 WEEK #10 WEEK #11
Operations/ Math & Tools Blueprint Tack Welding Tack Welding Tack Welding Shipfitting Shipfitting Shipfitting Assessment
Careers Measurement Reading
Ship Safety Fire Watch Cutting & Continuous
Terminology Burning Improvement
Math & Tools Blueprint Tack Welding Rigging
Measurement Reading
Cutting & Professional
Burning You
34 hours 34 hours 34 hours 34 hours 34 hours 34 hours 34 hours 34 hours 34 hours 34 hours 17 hours
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Tack Welding Instructor’s Guide Preparing to Teach
Preparing to Teach
In this section, you will find a universal model to use for organizing the instruction for
each module in this curriculum around the learner’s needs. The PowerPoint for this
course is designed using this format. Follow this approach each time you deliver a
training module within this curriculum. This section also includes a list of all the
materials needed for the completion of each activity and a space for you to prepare an
introduction of yourself to the class.
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Course Design
This training program is designed so that each module follows a framework that
provides a consistent approach for delivering instruction and meeting learner needs.
Each part of this framework answers key questions that learners have. The essential
components of the framework and the questions each answers are as follows:
1. About the Module (Opening)—Who are you? Where am I? What is this

about? (These are answered in the instructor introduction, course introduction
and orientation to the program.)
2. Objectives—What’s expected of me? (This is answered at beginning of course
and throughout training.)
3. WIIFM (What's In It For Me)—Why is this important? (This is answered at
beginning of course and reinforced throughout training.)
4. Content—How do I do it? (This is answered throughout the training.)
5. Practice and Feedback—Can I try it? How did I do? (This is answered through
activities and labs.)
6. Skill Check—Have I got it? (This is answered through pre and post-course
assessments of both knowledge and application including the comprehensive
final for the entire curriculum. The activities, labs and quizzes also contribute to
the skill check portion of the course.)
7. Summary—Where are we now? (This is answered by reviewing the highlights of
the course.)
8. Close (Moving On)—Where do we go from here? (This is answered by giving
learners a brief overview of the next course in the entry-level shipfitter curriculum
or, if this was taught as a stand-alone course, what are their “next steps” in
applying this new learning.)
Prepare for this training using this format, and follow it throughout the course to allow for
greater efficiency in delivery while also meeting the needs of the participants.
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Materials List
Tack Welding
1. Personal Protective Equipment
2. Things not to wear when welding
3. Simulated shipyard environment for observing tack welding
4. Welding accidents video clip
5. Simulated shipyard environment for observing SMAW tack welding
6. Examples of a bad and good tack weld
7. Equipment and setting for preparing and cleaning work surfaces
8. Samples sets of tack welding standards
9. AWS Code Book
10. Environment for demonstrating welding positions: flat, horizontal, vertical &
overhead
11. Samples of structural components
12. SMAW Equipment: Work piece, work clamp, electrode holder
13. Hook up equipment for DCEP and DCEN welding machine leads
14. Welding machines and power functions
15. Cable and cable connections
16. SMAW ground clamps and attachments
17. Hand tools for cleaning/preparing work surfaces
18. Electrodes (various ones used for tack welding)
19. Equipment/materials for testing base metal and electrode compatibility
20. Low-hydrogen E7018 electrodes
21. Weld coupon samples
22. Materials for striking an arc
23. Materials/equipment for fillet tack welding
24. Weld coupons and electrodes for practice tack welding (enough for all students)
25. Two pieces of flat bar and associated materials needed for each student to
complete tack welding application assessment
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Course Competencies
This list represents the core competencies that entry-level shipfitters should be able to
demonstrate as a result of this training.
1. Practice safety regulations established for SMAW procedures

2. Wear correct PPE when tack welding
3. Recognize safety signs and signals on the job
4. Distinguish between welding and tack welding
5. Follow tack welding quality standards
6. Identify tack welding types, parts and materials
7. Prepare weld surfaces and recognize the impact of grinding, preheating, on
welding materials
8. Recognize structural components and shapes
9. Recognize SMAW equipment
10. Setup and operate SMAW equipment safely
11. Adjust basic power supplies for improved tack weld quality
12. Attach welding leads, cables, electrodes and ground clamps safely and
according to specification
13. Recognize common electrodes used for tack welding and their role in the
welding process
14. Select electrodes (rods) appropriate for a specific tack weld project
15. Identify electrodes based on code classifications
16. Determine the best applications for low hydrogen electrode groups
17. Handle and store electrodes according to procedures
18. Strike an arc for tack welding
19. Tack fillet and groove welds in every position using 6011 and 7018 electrodes
according to AWS standards for tack welders
20. Recognize the characteristics of good and bad tack welds
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Instructor Introduction
Directions: In the space below, make notes of special information you want to share
with the participants regarding your qualifications to teach this course as well as your
training and facilitation style.
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Tack Welding Instructor’s Guide Tack Welding Answer Guide
Tack Welding Answer Guide
The following directions/answers correlate with the activities in this course.

Presentation activities are offered throughout this section of the guide to give you ideas
on how to instruct using accelerated learning techniques. You are encouraged to use
these presentation ideas and add others as appropriate to offer ways to more fully
engage participants in the learning process. Whenever possible, limit all lecture-type
instructional approaches to 15 minutes or less.
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Course Introduction
Directions: Play fun music in the background while class assembles. Whenever
possible, lay out equipment in room for viewing by students. Set up the learning
environment to provide as many topic-related items as possible (tools, parts, etc.)
Make any necessary introductions of course materials including module lessons and
objectives. Always post objectives on the training room wall so that they are in
full view of learners at all times.
Tack Welding
Slide 1
Ship Terms
• Introduction
• Course Overview
Slide 2
Course Objectives
• Practice safety • Identify tack
welding parts,
• Distinguish types and
between welding materials
and tack welding
• Setup and
• Follow tack operate SMAW
welding standards equipment
Slide 3
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Presentation Activity—Course Benefits

Directions: Pose the “What’s in this for you?” question. Allow learners to offer their own
understanding of how they can benefit from the course. This is an opportunity to gain
the “buy-in” of the learners and let them take ownership of the learning. Use the space
below to consider your own ideas of how they may benefit.
Make this activity physically active by posting flipchart paper on two separate walls
creating a kind of “graffiti wall”. Split the class in half, give them markers and let them
write on the paper the benefits they will receive from the training. They can write words
or draw pictures. It’s their wall of benefits!
(Optional): Combine this activity with a brief introduction for the participants as needed.
Have them turn to each other and introduce themselves. Then, have them very briefly
share who they are with the large group.
Instructor Note: Complete the graffiti-writing activity only when this course is
being taught as a stand-alone module. When teaching the entire curriculum,
curriculum, complete it just once during the first module.
Benefits
How would an entry-level shipfitter benefit from

learning to produce quality tack welds?
Slide 4
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Tack Welding Instructor’s Guide Lesson 1—Tack Welding Safety
Lesson 1 Introduction
Directions: Introduce the topics and objectives for Lesson 1 in PG (p. 7, Slide 5).
Tack Welding Safety

• Practice safety
regulations
• Wear correct PPE
• Recognize safety
signs and signals
Slide 5
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Lesson 1—Tack Welding Safety
Lesson Overview
In this lesson, you'll learn about the safety
practices required when tack welding. A
shipyard tour will provide exposure to safety
regulations and procedures being
implemented in a work setting. This lesson
also introduces the personal protective
equipment (PPE) that must be worn on the
job.
Lesson Learning Objectives

After completing the Tack Welding Safety lesson, participants will be able to:
Practice safety regulations established for SMAW procedures
Wear correct PPE when tack welding
Recognize safety signs and signals on the job
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Lesson 1 – Part 1
Directions: Discuss the following topics from the Participant Guide:
Topic Participant Guide Page

Tack Welding Safety 8, Slides 6-7
PPE Illustration 9, Slide 8
Personal Protective Equipment (PPE) 10
Lab 1: Wearing Personal Protective Equipment 11, Slide 9
Activity 1: Observe Tack Welding 12, Slide 10
Instructor Note: Have a set of PPE available for demonstration/completion of

Lab 1.
What’s the Difference?

Tack Welding Safety. Define welding and explain the
difference between welding and tack welding (p. 8, Slide 6).
The size of the weld!
Describe hazards associated with welding—electricity,
fumes and gases, risk of fire/explosions, etc.—and explain
6 that safety should be the worker’s number one priority (p. 8).
Slide 6
Review the factors that lead to hazardous conditions (p. 8,

Site Accidents
• Mental/physical • Foot & vehicle Slide 7).
stress traffic congestion
• Medications, illness • Hurried shift

or injury changes
• Alcohol and drug • Faulty or

abuses damaged
equipment
Slide 7
PPE Illustration. Refer learners to image (p. 9, Slide 8).

PPE Illustration
Discuss the importance of PPE and encourage students to
become familiar with it. Note that the workers’ boots are not
pictured and briefly describe the type boots that should be
worn when tack welding (p. 9, Slide 8).
8
Personal Protective Equipment (PPE). Review

appropriate PPE for tack welding (p. 10).
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Ask learners to complete Lab 1: Wearing Personal

Lab 1: Wear PPE
• Observe how Personal Protective Protective Equipment (p. 11, Slide 9) after modeling
Equipment should be worn when welding.
appropriate PPE.
Slide 9
Ask learners to complete Activity 1: Observe Tack Welding

Observe Tack Welding
(p. 12, Slide 10).
• Activity 1: Pay attention to what you see,
hear, feel and smell in the environment
while observing tack welding in action.
10
Slide 10
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Lab 1: Wearing Personal Protective Equipment

Directions: Watch as your instructor demonstrates how to wear personal protective
equipment when welding. S/he will also show you things not to wear when welding and
review the primary precautions you should take to be safe when welding. Afterwards,
you will have an opportunity to wear the PPE and get familiar with how it feels and looks
when used properly.
Take notes below.
NOTES

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Activity 1: Observe Tack Welding

Directions: Your instructor will provide a simulated shipyard environment for you to tour.
During the tour, you will observe demonstrations of tack welding. Use the safety
information on the following pages to serve as a guide for identifying safety procedures,
safety equipment, safety signs and the like that are all part of the world of tack welding.
Pay close attention to what you see, hear, feel, and smell in the environment. Ask
questions for understanding.
Take notes below.
NOTES
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Lesson 1 – Part 2

Safety Precautions 13-22, Slide 11
Activity 2: Welding Accidents Video 23, Slide 12
Lab 2: SMAW Tack Welding 24, Slide 13
Quiz: Tack Welding Safety 25-26, Slide 14
Application Assessment: PPE 27, Slide 15
Instructor Note: Have welding accidents video such as the CSB’s Dangers of
Hot Work available to show class for Activity 2. This video is
also embedded in PowerPoint slide 12. Have students bring
PPE to class for Application Assessment: PPE.
Safety Precautions
Review the safety precautions associated with welding (pp.
13-22, Slide 11):
 Electric Shock Can Kill (pp. 14-15)

 Fumes and Gases Can Be Hazardous (p. 16)
11
 Arc Rays Can Burn Eyes and Skin (p. 17)
Slide 11  Welding Can Cause Fire or Explosion (p. 18)
 Other precautions (pp. 19-22)
Ask learners to complete Activity 2: Welding Accidents

Welding Accidents Video
Video (p. 23, Slide 12).
• Activity 2: Watch video and discuss
questions.
Insert (wel ding) Photo Here
Chemical Safety Board’s Dangers of Hot Work

Video
12
Slide 12
Complete Lab 2: SMAW Tack Welding (p. 24, Slide 13).

Lab 2: SMAW Tack Welding
• Observe and listen as SMAW tack
welding is being performed.
Slide 13
©
Review the key learning points and ask learners to complete

the Tack Welding Safety quiz (pp. 25-26, Slide 14). Review
Tack Welding Safety Quiz results with class.
Test Your Knowledge!
14
Slide 14
Have students complete the Application Assessment: PPE

(p. 27, Slide 15).
PPE Application
Assessment
15
Slide 15
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Activity 2: Welding Accidents Video

Directions: Your instructor will now show you a video segment that shows welding
accidents. It will be very easy to see that wearing the proper protective gear and taking
simple precautions can help you avoid most accidents. After each video, discuss the
following questions:
1) What personal protective gear was the worker wearing? Was there anything
missing?
2) What led to the unsafe situation?
3) How could the people involved have worked more safely?
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Lab 2: SMAW Tack Welding

Directions: Your instructor will provide you with a simulated tour of a shipyard where
tack welding is being performed using SMAW. Observe and listen as your instructor
points out various activities and explains the hazards involved with the tasks being
performed. Use the space below to record things you want to remember.
NOTES
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Quiz: Tack Welding Safety

Instructor Note: Review the key learning points before learners take quiz in
PG (pp. 25-26, Slide 14).
Tack Welding Safety Quiz
14
Slide 14
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Quiz: Tack Welding Safety
Directions: Circle the correct answer for each question or statement.
1. True or False: In tack welding, goggles can be used for protection instead of hoods.
a. True
b. False
2. True or False: Breathing fumes and gases from welding is NOT hazardous to your
health.
a. True
b. False
3. True or False: Welding hoods should be fitted with the proper shade of filtered lens
to protect your face and eyes when tack welding.
a. True
b. False
4. What three pieces of protective gear are required when tack welding?
a. Earplugs, fire-resistant gloves, cuffed pants
b. Earplugs, fire-resistant gloves, long sleeves
c. Steel-toed boots, goggles, earplugs
5. Do not block or filter airflow to welding unit because it will ____________________.

a. Create hazardous sparks
b. Cause it to overheat
c. Create a time-out on the machine
d. All of the above
6. Welding, chipping, wire brushing, and grinding cause sparks and flying metal. As
welds cool, they can throw off slag. To protect yourself from injury you should:
a. Never grind or use a wire brush
b. Always wait until the weld cools to chip or grind
c. Wear approved safety glasses with side shields even under your
welding helmet.
7. True or False: Electric arcs should never be viewed directly or indirectly with the
naked eye.
a. True
b. False
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8. Clamp work cable with good metal-to-metal contact to ground or to worktable as

near the weld as practical in order to _______________________________.
a. Prevent electric shock
b. Avoid an unstable work area
c. Provide proper insulation
9. What are some factors that lead to hazardous work conditions?

a. Mental or physical stress
b. Medications, illness or injury
c. Age and inexperience
d. Alcohol or illegal drug use
e. All of the above
10. Welding can cause fire or explosion. What are some things you do to prevent this
from happening?
a. Wear oil-free protective garments such as leather gloves, heavy shirt,
cuffless trousers, high shoes, and a cap
b. Remove any combustibles, such as a butane lighter or matches, from your
person before doing any welding
c. Remove stick electrode from holder or cut off welding wire at contact tip
when not in use
d. Both a and c
e. All of the above
©
Application Assessment: PPE
Directions: Your instructor will provide you with the standard PPE that must be worn
when tack welding. Demonstrate how to put on the equipment in preparation for tack
welding.
Instructor Note: Allow extensive question and answer sessions to ensure

understanding. Have learners partner individually
demonstrate putting on and wearing PPE. Have learners
critique each other’s performance.
Watch and observe closely to ensure learning is occurring

and proper techniques are being demonstrated.
Guide learners in correcting each other.
Optional: Provide a piece of PPE that is faulty in some way

and mix it in with all the other PPE. Challenge learners to
find anything wrong with PPE that would impair its ability to
protect them.
©
Tack Welding Instructor’s Guide Lesson 2—Tack Welding Basics
Directions: Introduce the topics and objectives for Lesson 2 (p. 29, Slide 16).
Tack Welding Basics

• Follow tack welding
quality standards
• Identify tack weld

types and structural
components
• Prepare weld
surfaces
16
Slide 16
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Lesson 2—Tack Welding Basics
Lesson Overview
In this lesson, you'll learn the distinct
differences between welding and tack
welding. Basic foundational pieces will be
covered such as welding types, parts and
materials along with key words or phrases
common to the trade.

After completing the Tack Welding lesson, participants will be able to:
Distinguish between welding and tack welding
Follow tack welding quality standards
Identify tack welding types, parts and materials
Recognize structural components and shapes
Prepare weld surfaces and recognize the impact of grinding and preheating, on
welding materials
©
Lesson 2 – Part 1

Welding Defined 30, Slide 17
Tack Welding 31, Slide 18
Good and Bad Tack Welds 32, Slide 19
Lab 3: Tack Welding Demonstration 33, Slide 20
Instructor Note: Have samples of good and bad tack welds. Have a booth
set up to demonstrate in the lab good and bad tack welds for
Lab 3.
Welding Defined. Describe what shipbuilding is—piecing

u1
Welding Defined
together a lot of different parts to form a whole. Note that
welding is a big part of this process. Remind learners what
• A fabrication process
that joins materials
into one piece by
melting and adding a
filler to form a pool of
molten material that
cools to become a
welding is (p. 30, Slide 17).
strong joint.
17
Slide 17
Tack Welding. Remind learners that tack welding is

u1
Tack Welding
welding—just short welds. Note that tack welding is
performed at the first stages of fitting in preparation for the
• Tack welding is a
“Short” weld.
final weld (p. 31, Slide 18).
18
Note the importance of accurate, smooth, clean, and
Slide 18 properly sized welds and how it could affect the welder’s job
(p. 31).
u1
Good and Bad Tack Welds. Introduce the term, distortion,
Good and Bad Tack Welds and its causes (p. 32, Slide 19). Note that tack welding helps
prevent butt joint distortion. Refer learners to the illustration
A Good Weld!
Tra vel to Fa st Tra vel Too Slow A mpera ge Too Low
on 32 and discuss the differences in good and bad tack
A mpera ge Too H igh Ar c Too Short A rc Too Slow
welds.
Note that shipfitters must qualify their skills when they apply
19
Slide 19 for a job at a shipyard and discuss the testing process and
expectations (p. 32).
©
Complete Lab 3: Tack Welding Demonstration (p. 33, Slide

Lab 3: Tack Welding Demo
• Observe a good and bad tack weld being
20).
demonstrated.
20
Slide 20
©
Lab 3: Tack Welding Demonstration

Directions: Watch as your instructor demonstrates:
A bad tack weld.

A good tack weld.
Instructor Note: Be sure to wear appropriate PPE and follow safety guidelines
associated with tack welding as well proper techniques.
Prepare to explain why one weld is good and one weld is
bad. Allow extensive question and answer sessions to
ensure understanding.
©
Lesson 2 – Part 2

Tack Welding Preparation 21, Slide 21
Lab 4: Tack Weld Surface Preparation 35, Slide 22
Instructor Note: Have wire brush, chipping hammer, and other tools used in
surface preparation. Have a booth set up to demonstrate
tack weld surface prep for Lab 4.
Describe the process for preparing a surface for tack welds.

u1
Tack Welding Preparation

Note that debris and spatter must be removed for the
workpiece to help ensure that the tack weld will be free from
defects (p. 34, Slide 21).
21
Describe the tools used in surface preparation and how to
use them properly.
Slide 21
Note that surface preparation is the shipfitter’s responsibility
and that the surface should be thoroughly cleaned after
each tack weld pass.
Complete Lab 4: Tack Weld Surface Preparation (p. 35,

Lab 4: Tack Weld Surface Prep
• Observe a tack weld surface being
Slide 22).
prepared.
22
Slide 22
©
Lab 4: Tack Weld Surface Preparation

Directions: Watch as your instructor demonstrates:
The process for preparing work surfaces for tack welding.

Cleaning the work surface after the tack weld is complete.
associated with surface prep. Encourage learners to make
notes and observe closely during this demonstration. Involve
them in the demonstration. Demo some steps and then have
participants repeat what you did. Allow extensive question
and answer sessions.
©
Lesson 2 – Part 3

Tack Welding Standards 36, Slide 23
Lab 3: AWS Welding Standards 37, Slide 24
Instructor Note: Have one or more copies of AWS’s D1.1 Structural Welding
Code Steel which outlines how tack welders should be
qualified (4.20.2-Tack Welders) and the extent of their
qualifications (4.20.2.1). Have these sections marked. If
possible have a sample set of shipyard tack welding
standards. Both documents will be used in Activity 3.
u1
Note that each shipyards has its own sets of standards for
Tack Welding Standards
• This course will
tack welding (p. 36, Slide 23). Reminder learners that they
provide you with
knowledge to
perform tack welding
will be tested to the yard’s standards before starting work.
Note that they will be classified based on their level of
procedures generally
required of entry-
level shipfitters at
performance and cannot work unless they pass the test.

most any shipyard.
Note that guidelines and standards for tack welding may be

23
Slide 23
provided based on project-specific criteria set forth in print
drawings. Introduce the concept of national recognized
standards such as those established by the American
Welding Society (p. 36).
Complete Lab 3: AWS Welding Standards (p. 37, Slide 24).

AWS Welding Standards
• Activity 3: Study tack welding standards

and American Welding Society (AWS)
Codes
24
Slide 24
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Activity 3: AWS Welding Standards

Directions: Your instructor will pass around a sample set of shipyard tack welding
standards along with a copy of the AWS code book. Flip through the pages and check
out the various codes provided.
Instructor Note: Review various codes in the code book. Point out specific
information that is critical for entry-level shipfitters to know
about tack welding standards and codes.
©
Lesson 2 – Part 4

Tack Welding Positions 38-39, Slide 25
Activity 4: Welding Position 39, Slide 26
Lab 5: Welding Position Demonstration 41, Slide 27
Instructor Note: Have sample workpieces that illustrate groove and fillet
welds.
Explain that tack welding parts, the shipfitter will be required

to weld in different positions.
u1
Explain and demonstrate the four welding positions—flat,

Tack Welding Positions
1—Flat
vertical, horizontal, overhead and refer learners to
2—Vertical
1‐F lat 2‐Vertical
illustrations (p. 38, Slide 25).
3—Horizontal
4—Overhead
3‐Horizontal 4‐Overhead Refer learners to illustration (p. 39) and introduce the
various welding designations that identify the weld joint and
the position of the weld—1G, 2G, 1F, 2F, etc. Give learners
25
the opportunity to identify the various welding positions and

Slide 25
tack welds using sample workpieces or illustrate them on a
whiteboard.
Ask learners to complete Activity 4: Welding Position

Welding Position Designations
Designations (p. 40, Slide 26).
• Activity 4: Identify welding position
designations.
– 2G
– 1F
– 3F
– 4G
26
Slide 25
Have a booth setup and complete Lab 5: Welding Position

Lab 5: Welding Position Demo
• Observe welding positions being demonstrated
Demonstration (p. 41, Slide 27).
and explained.
27
Slide 27
©
Activity 4: Welding Position Designations

Directions: Identify the following designations for welding positions:
2G— Horizontal Position Groove Weld
1F— Flat Position Fillet Weld
3F— Vertical Position Fillet Weld
4G— Overhead Position Groove Weld
Instructor Note: Review answers and field questions.
©
Lab 5: Welding Position Demonstration

Directions: Watch as your instructor demonstrates the following welding positions:
1. Flat
2. Horizontal
3. Vertical
4. Overhead
S/he will also explain specifics relative to successful welding in each position. Ask
questions for clarity. After listening and observing the demonstration, you will have a
chance to practice holding SMAW equipment in these positions.
associated with tack welding as well as proper techniques.
Provide insights into successful welds from each position.
Involve participants as much as possible in the
demonstrations. While practicing, have participants explain
what they are doing and have them critique each other for
accuracy.
©
Lesson 2 – Part 5

Structural Components and Shapes 42, Slide 28
Structural Members 43-46, Slide 28
Structural Member Identifiers 47-49, Slide 29
Lab 6: Structural Components 50, Slide 30
Terminology 51, Slide 31
Quiz: Tack Welding Basics 52, Slide 32
Instructor Note: Have examples of the following structural members and

shapes on display—I-Beam, H-Beam, T-Bar, angle,
channel, square tubing, flatbar, Z-Bar, Bulb Bar, Solid Half
Round, Hollowed Half Round. These will also be used for
Lab 6.
Structural Components and Shapes. Review the list of

u1
Structural Components/Shapes
1. I-Beam
commonly used components and shapes (p. 42, Slide 28).
Refer to structural members and shapes on display.
2. H-Beam
3. T-Bar Flat Bar
4. Angle I-Be am
H -Bea m
5. Channel
7. Square Tubing A ngle
Structural Members. Note that structural members are the

9. Flat Bar
Square Tubing T-Bar Channe l
28
parts (shapes) that are prefabricated or created on the
Slide 28 shipyard that are designed to be fitted and tacked to various
plates for ship construction (p. 43, Slide 28).
Review the illustrations of the structural components,

showing learners examples on display and reviewing the
purpose of each (pp. 43-46, Slide 28).
Structural Member Identifiers. Review the identifiers for

u1
Component Identifiers
the following structural members—I-Beam, T-Bar, Angle,
Channel, H-Beam, Z-Bar, Bulb Angle, Flanged Plate (pp.
47-49, Slide 29.
29
Slide 29
©
Ask learners to complete Lab 6: Structural Components (p.

Lab 6: Structural Components
• Study structural components.
50, Slide 30).
30
Slide 30
Terminology. Note that there are a number of “buzz” words

Tack Welding Terms
or slang words that learners will hear on the job that varies
Rod
• Use the glossary
of terms in your
from yard to yard. Encourage them to ask if they hear a term
PG to learn new
words! with which they are unfamiliar (p. 51, Slide 31).
31
Slide 31

the Tack Welding Basics quiz (pp. 52-53, Slide 32). Review
Tack Welding Basics Quiz results with class.
32
Slide 32
©
©
Lab 6: Structural Components
Directions: Your instructor will show you samples of structural components that you will
work with when tack welding parts. Study the samples and ask questions for clarity.
Prepare to identify any of the following when prompted by your instructor:
Angle Bar
Square Bar
Channel
Plates
I-Beam
H-Beam
Zee Bar
Tee Bar
Bulb Bar
Solid Half Round
Hollowed Half Round
Flat Bar
Square Tubing
Instructor Note: Tailor this review to the needs of the group. Spend more
time reviewing any areas of weakness.
©
Quiz: Tack Welding Basics

PG (pp. 52-53, Slide 32).
Tack Welding Basics Quiz

32
Slide 32
©
Quiz: Tack Welding Basics

1. Tack welding actually is welding; it is just a short weld.

a. True
b. False
2. There are no standards or codes of performance for tack welding once you have
learned the basic procedures.
a. True
b. False
3. The primary types of welds that tack welders work with are fillet and groove.
a. True
b. False
4. The structural components and shapes most commonly used in shipfitting include
the following:
a. I-Beam, H-Beam, Tee Bar, Angle, Channel, Square Tubing & Flat
Bar
b. Angle, Channel, Pipe, H-Beam, I-Beam, Tee Bar & Flat Bar
c. Channel, Pipe, H-Beam, I-Beam, Tee Bar and Eyebolt
5. A fillet plate weld in a horizontal position would be written as what?

a. 1F
b. 2F
c. 3F
d. 4F
6. There are certain identifiers that are unique to several of the structural members
common to fitting. What are they?
a. Flange, Toe, Heel, Bosom, Fillet, Web, Stem
b. Flange, Heel, Head, Toe, Bosom, Fillet
c. Web, Toe, Head, Foot, Flange, Heel
7. Tack welding helps prevent butt joint distortion by tacking the materials in position
before the final weld.
a. True
b. False
©
8. If a tack weld of 3/16 inches is required, a 1/2 inch tack weld will create an oversized
tack. Will this allow the final welder to weld to specification?
a. Yes
b. No
c. Not enough information
9. After each weld pass, what should be done?

a. Grind surface smooth
b. Spray the weld off with water
c. Surfaces should be thoroughly cleaned before starting a new tack weld
d. Nothing, move on to the next tack weld
10. The certification process for tack welding will vary from shipyard to shipyard. Each
facility will dictate the size of the tack weld test such as whether it will need to be six
inches in length or longer.
a. True
b. False
©
Tack Welding Instructor’s Guide Lesson 3—Shielded Metal Arc Welding (SMAW) Equipment
SMAW Equipment
• Setup and operate
SMAW equipment
safely
• Adjust basic power
supplies
• Attach welding leads,
cables, electrodes
and ground clamps
33
Slide 33
©
Lesson 3—Shielded Metal Arc

Welding (SMAW) Equipment
Lesson Overview
In this lesson, you'll learn about the basic
equipment and processes behind Shielded
Metal Arc Welding (SMAW). Identification,
set-up and operation of SMAW equipment will
be covered including the basic power sources
of welding machinery and their impact on
effective tack welding.

After completing the Shielded Metal Arc Welding Introduction lesson, participants will be
able to:
Recognize SMAW equipment
Setup and operate SMAW equipment safely
Adjust basic power supplies for improved tack weld quality
Attach welding leads, cables, electrodes and ground clamps safely and
according to specification
©
Lesson 3 – Part 1
Topic Page, Slide #

Shielded Metal Arc Welding (SMAW) 56-57, Slide 34
SMAW Features 58, Slide 35
Lab 7: SMAW Demonstration 59, Slide 36
Instructor Note: Have booth set up for SMAW welding demonstration for Lab
7. Have sample electrodes on display.
Shielded Metal Arc Welding (SMAW). Note that the

primary welding processing that fitters use is Shielded Metal
Arc Welding (SMAW) (p. 56, Slide 34).
Describe the SMAW process, introducing the terms arc,

electrode, flux, slag, bead (p. 56).
Slide 34 Explain that the process requires electrical circuit; review
illustrations on p. 57.
SMAW Features. Refer learners to the illustration on p. 58

SMAW Features
1. Stick Welding Power Source—Constant Current
(CC), AC or DC
while reviewing the parts involved in the SMAW process (p.
2. Insulated Electrode Holder (whip)
3. Workpiece
58, Slide 35). Review the parts on SMAW equipment in the
lab.
4. Work Clamp
35
Slide 35
Complete Lab 7: SMAW Demonstration (p. 59, Slide 36).

Lab 7: SMAW Demo
• Observe basic hook up and features of
SMAW process.
Welding Ma chine
G round Lead
On
Electrode Holder
Off
Electrode
+ -
Arc
Workpiece
Electrode Lead
36
Slide 36
©
Lab 7: SMAW Demonstration

Directions: Your instructor will demonstrate for you the basic hook up and features of
the SMAW process. Listen and observe. Ask questions for clarity.
NOTES
Instructor Note: Involve participants as much as possible in the

demonstration
©
Lesson 3 – Part 2
Topic Page/Slide #
Voltage and Current 60, Slide 37
Amperage 61, Slide 38
Welding Leads and Polarity 62, Slide 39
Lab 8: Hooking up Welding Leads 64, Slide 40
7. Have sample welding machine and electrodes on display.
Voltage and Current. Note that in a welding circuit, power

Voltage and Current
• Voltage is actually the measure of
is measured in voltage and current (p. 60, Slide 37). Define
current flow:
– Voltage and Current
– Voltage (Volts)
voltage—the measure of current flow. Explain that voltage is
– Current
what pushes the energy through resistance to its destination
LEARN THIS SYMBOL!
This is the interna tional safety symbol for high voltage. It
means “CAUTION, RISK OF ELECTRIC SHOCK.”
(p. 60). Note that the higher the voltage, the greater the
37
current flow will be.
Slide 37
Explain that this is important to know because the amount of
current flow or voltage provided when tack welding will
directly impact the arc produced.
Note that voltage must be managed carefully since different

rods burn at different voltages. Give examples of what will
happen if voltage is incorrect—a rod that burns too cold will
stick; a rod that burns too hot will melt too fast.
Review the three terms—voltage and current, voltage

(volts), and current (p. 60).
Call learners attention to the safety symbol for high voltage

and note that it means caution, risk of electric shock (p. 60).
Amperage. Explain that amperage is intensity. Note that

Amperage
the intensity or amperage of the current directly impacts tack
Amperage = Intensity
weld quality because this is the heat source (p. 61, Slide
38). Note that the higher the amperage, the more heat
produced.
38
Slide 38 Explain that amperage needed to tack weld depends on

electrode diameter, size and thickness of the pieces to be
tacked, and the welding position. Note that the thicker the
rod, more amperage will be needed (p. 61).
©
Review the bulleted items related to amperage (p. 61).
Note that a smaller electrode and lower amperage is

typically needed to tack weld a small piece as compared to
a large piece of the same thickness. Note, too, that thin
metals require less current that thick metals, and a small
electrode requires less amperage than a large one (p. 61).
Welding Leads and Polarity. Explain what welding leads

Welding Leads and Polarity
are. Note that they are typically designed with the end of
one lead holding the electrode while the end of the other
Polarity =
Direction of
current flow
Welding lead that
holds ground clamp
Welding lead that
holds electrode
lead holds a clamping device to be attached to the ground.
holder
Note that the opposite ends of the leads have connectors

39 that plug into the welding machine or power source (p. 62,
Slide 39 Slide 39).
Define polarity—direction of current flow—and introduce the

concepts of Direct Current Electrode Positive (DCEP) (p. 62)
and Direct Current Electrode Negative (DCEN) (p. 63).
Refer learners to illustrations on the topic (pp. 62-63). Note
that DCEN is primarily used for flat position welding because
more heat is generated at the workpiece.
Explain that how welding leads are connected to either the

ground or the welding machine determines polarity. Note
that polarity only applies to direct current (DC). Explain that
Alternating Current (AC) does not have a polarity because
the current is constantly alternating from one direction to the
other.
Explain that when using DC current, it is understood that the

current travels from negative (-) to positive (+). Note that the
process cannot be changed but the path of the current can
be changed.
Complete Lab 8: Hooking Up Welding Leads (p. 64, Slide

Lab 8: Hooking Up Weld Leads
• Observe the hook up of DCEP and DCEN
40).
weld leads.
40
Slide 40
©
Lab 8: Hooking Up Welding Leads

Directions: Your instructor will demonstrate how to hook up DCEP and DCEN welding
machine leads. Afterwards, you will have a chance to practice making the hook-ups
yourself.
Instructor Note: Have participants work in partners to practice. Randomly ask

them to demonstrate various hook ups. Also, have some
individuals demonstrate hook ups and explain what they are
doing while they are doing it.
©
Lesson 3 – Part 3
Topic Page/Slide #
SMAW Equipment 65, Slide 41
SMAW Equipment Selection 66, Slide 42
Exercise: Equipment Selection 67, Slide 43
Electrode and Amperage Selection Chart 68, Slide 44
Lab 9: Welding Machine Demonstration 69, Slide 45
Instructor Note: Have welding machine on display for demonstration or use

welding machines in lab.
SMAW Equipment. Note that welding machines are

SMAW Equipment
• AC—alternating
classified by the electrical current they produce—AC, DC,
only
• DC—direct only AC/DC (p. 65, Slide 41).
• AC/DC—both
alternating and
direct
Explain that machine classifications indicate the type of

welding procedure that the machine is designed to support.
Note that SMAW procedures are supported by welding
41
Slide 41 machines that only produce DC welding voltage and current.

Explain if the DC varies between higher open-circuit and
lower voltage, it is considered to be a variable-voltage
constant-current power source, which is also used for
GTAW or gas tungsten arc welding (p. 65).
Equipment Selection. Review the list of factors affecting

SMAW Equipment Selection
• Identify:
the selection and setup of the SMAW welding machine—
– Welding process
– Welding current
– Maximum
process, welding current, maximum amperage, primary
amperage
– Primary power
connections
power connectors (p. 66, Slide 42).
42
Slide 42
Exercise: Equipment Selection. Walk through the

Exercise: Equipment Selection
• Welding process? Equipment Selection exercise (p. 67, Slide 43).
• Welding current?
• Maximum
amperage?
• Primary power
connections?
Slide 40
43
Slide 43
©
Introduce the Electrode and Amperage Selection Chart

Electrode/Amperage Selection
(p. 68, Slide 44). Explain how to read the chart and give
learners several different electrode types/sizes to look up on
the chart.
44
Slide 44
Complete Lab 9: Welding Machine Demonstration (p. 69,

Lab 9: Weld Machine Demo
• Observe how a welding machine functions
and how the power sources vary.
Slide 45).
45
Slide 45
©
Lab 9: Welding Machine Demonstration

Directions: Your instructor will demonstrate how each welding machine functions. S/he
will also show you how the power sources vary among them.
Instructor Note: Involve participants as much as possible in the

demonstration. Include additional opportunities for learners to
read the Electrode and Amperage Selection Chart. Be sure to
complete an extensive question and answer session.
©
Lesson 3 – Part 4

String Welding Lead 70, Slide 46
Welding Lead End Connections 71, Slide 47
Lead Control Quick Reference Guide 72, Slide 48
10. Have sample welding leads with different connectors—
ground clamp, lug, electrode holder—on display.
String Welding Lead. Explain that the first step in setting

String Welding Lead
• After machine
up the welding machine is to string the welding lead (p. 70,
selection, first
string the
welding lead.
Welding
lead.
Slide 46). Note that they are available in many sizes and are
designed to carry the current produced by the welding
machine.
46
Explain that the larger the welding lead, the more current it
Slide 46 can conduct. Note that the distance traveled impacts the
selection of line size because the longer the current has to
travel, the less heat it will produce.
Weld Lead End Connections

Welding Lead End Connections. Explain that in order to
• Proper end connections need to be made
to effectively setup welding leads.
properly set up welding lead, proper end connections have
to be made using lugs, quick disconnects, ground clamps or
electrode holders. Describe the purpose of each of the
connectors (p. 71, Slide 47). Note that connections should
G round Clam p
Lugs E lectrode Holder
47 be secured tightly to avoid overheating.

Slide 47
Lead Control Quick Reference Guide. Review safety

Lead Control considerations that should be followed in order to safely
control welding leads (p. 72, Slide 48).
Use the lead control quick reference guide!

48
Slide 48
©
Complete Lab 10: Hooking Up Welding Leads (p. 73, Slide

Lab 10: Cable Connections
• Observe how to make cable connections
and string cable safely.
49).
• Practice working with a partner.

49
Slide 49
©
Lab 10: Cable Connections and Stringing Cable

Directions: Your instructor will demonstrate how to make cable connections and string
cable safely. Then, you will be provided with the cables and work area for stringing
cable in preparation for tack welding. Work with a partner and follow the instructions in
your quick reference guide to properly string the cable for a safe tack weld operaton.
Your instructor will provide you with directions and feedback as needed.
Instructor Note: Observe participants closely to make sure they are using the
guide and working with cable safely and accurately. Give
specific feedback during and after their performance.
©
Lesson 3 – Part 5
Topic Page/Slide #
Electrode Holders 74, Slide 50
Ground Clamp Location 75, Slide 51
Workpiece Clamp Location Quick Reference Guide 76, Slide 52
Lab 11: Attaching a Ground Clamp 77, Slide 53
Instructor Note: Have booths set up for demonstration of and practice

attaching ground clamps for Lab 11. Have sample
electrodes, electrode holders, ground clamps, and work and
ground leads—on display.
Electrode Holders
Electrode Holders. Explain that purpose of electrode
Electrode holders are used to
grip the electrode while the tack
holders—they grip the electrode while the tack weld is being
weld is being completed.
performed (p. 74, Slide 50). Note the safety precautions that
should be followed when using electrodes (p. 74).
50
Slide 50
Ground Clamp Location. Review the types of leads—

Ground Clamp Location
electrode lead and work lead—and their purpose (p. 75,
Slide 51).
Ground clamps form a
connection between the
Explain the purpose of ground clamps—they form a

material being worked and the
lead serving as a return path for
electrical current.
51
connection between the material being worked and the lead
serving as a return path for electrical current (p. 75, Slide
Slide 51
51). (If needed, review the electrical circuit illustration on p.
57.)
Workpiece Clamp Location Quick Reference Guide.

Ground Clamp Location Discuss the importance of proper placement of the
workpiece clamp (p. 76, Slide 52). Remind learners that
welding current is passing through to the clamp. Note that
the arcing created by the current can cause severe damage
Use the Workpiece Clamp Location Quick
Reference Guide!
to surrounding seals, bearings, valves, etc., if current
passes through them.
52
Slide 52
©
Review the bulleted list of items relating to workpiece clamp

location (p. 76, Slide 52).
Complete Lab 11: Attaching a Ground Clamp (p. 77, Slide

Lab 11: Attach a Ground Clamp
• Observe how to attach a ground clamp
53).
for SMAW.
• Practice working with a partner.

53
Slide 53
©
Lab 11: Attaching a Ground Clamp

Directions: Your instructor will demonstrate how to attach a ground clamp safely and
correctly for SMAW. Then, you will be provided with the SMAW equipment to locate the
workpiece clamp yourself. Work with a partner and follow the instructions in your quick
reference guide to properly setup the workpiece clamp. Your instructor will provide you
with directions and feedback as needed.
NOTES
Instructor Note: Observe learners closely to make sure they are using the
guide and attaching the clamp safely and accurately. Give
specific feedback during and after their performance.
©
Lesson 3 – Part 6
Topic Page/Slide #
Tack Welding Cleaning and Hand Tools 78, Slide 54
Welding Equipment Safety Cheat Sheet 80, Slide 56
Lab 12: Using Hand Tool to Clean and Prepare Work 79, Slide 55
Surfaces
Quiz: Shielded Metal Arc Welding (SMAW) 81-83, Slide 57
Instructor Note: Have two coupons with tack welds on display—one should
have welds that were cleaned properly and one should have
welds that were not prepped properly. Have a wire brush,
chipping hammer, needle gun, grinder, and scaling gun on
display for discussion and demonstration.
Tack Weld Cleaning and Hand Tools. Note that the

Tack Weld Cleaning
success of any weld depends upon how well the surface has
Common Cleaning Tools:
been cleaned before and after the process (p. 78, Slide 54).
Explain that if slag is not cleaned off a weld, it can impair the
•Chipping hammers
•Wire brushes
•Needle guns
ability to make another effective weld pass.

•Grinders
•Scaling guns
54
Using tools on display—chipping hammers wire brushes,

Slide 54
needle guns, grinders, and scaling guns—review how each
tool is used to clean welds (p. 78).
Complete Lab 12: Using Hand Tools to Clean and Prepare

Lab 12: Use Hand Tools
• Observe how to use hand tools to clean
and prepare surfaces.
Work Surfaces (p. 79, Slide 55).
55
Slide 55
Welding Equipment Safety Cheat Sheet. Review and

Welding Equipment Safety
discuss the safety reminders (p. 80, Slide 56). Give real-
world examples of issues you have experienced because
safety guidelines were not followed.
Use the Welding Equipment Safety Cheat Sheet!

56
Slide 56
©

the Shielded Metal Arc Welding (SMAW) Equipment quiz
SMAW Equipment Quiz (pp. 81-83, Slide 57). Review results with class.
57
Slide 57
©
Lab 12: Using Hand Tools to Clean and Prepare Work

Surfaces
Directions: Your instructor will demonstrate how to use hand tools to clean and prepare
work surfaces. Listen and observe. Ask questions for clarity. Later when practicing
tack welding, you will have many opportunties to practice cleaning work surfaces using
these tools.
NOTES
associated with cleaning and prepping work surfaces during
demonstration. Involve learners as much as possible in the
demonstration. Be sure to complete an extensive question
and answer session.
©
Quiz: Shielded Metal Arc Welding (SMAW) Equipment
PG (pp. 81-83, Slide 57).
SMAW Equipment Quiz

57
Slide 58
©
Quiz: Shielded Metal Arc Welding (SMAW) Equipment

1. True or False: The longer the distance a welding cable has to get to the workpiece,
the less heat that is produced.
a. True
b. False
2. True or False: The electrical disconnect for a welding machine should be identified
before hookup and use so that in an emergency the power source can be quickly
disabled.
a. True
b. False
3. True or False: The work clamp that attaches to the workpiece serves as a ground
when welding.
a. True
b. False
4. Shielded Metal Arc Welding (SMAW) is also called _______________ welding.

a. Stick
b. Rod
c. Electrode
d. Hot
5. Label the parts of the welding circuit on the diagram below:
Welding machine/power source
On Ground lead
Off
Electrode Holder
Electrode
+ -
Arc
Workpiece
Electrode Lead
©
6. True or False: When using the SMAW process to weld, the electrical circuit is NOT
closed until the electrode touches the workpiece.
a. True
b. False
7. What is the primary material used when performing Shielded Metal Arc Welding?
a. Flux
b. Electrode
c. Bead
d. Low Hydrogen Steel
8. The outer coating on an electrode is called __________.

a. Heavy coating
b. Shield
c. Arc
d. Flux
9. The direction electrical current flows in a direct current welding circuit is called
polarity.
10. Which of the following parts are involved in the SMAW process?
a. Stick welding power source
b. Insulated electrode holder (whip)
c. Workpiece
d. Work clamp
e. All of the above
11. What does this international symbol mean?

a. Caution, risk of electric shock
b. Beware, high voltage in area
c. Work safely, shock may occur
d. None of the above
12. True or False: A smaller electrode and lower amperage is usually needed to tack
weld a small piece as compared to a large piece of the same thickness. Thin metals
require less current than thick metals, and a small electrode requires less amperage
than a large one.
a. True
b. False
13. To select the right SMAW Machine you need to identify which of the following?
a. Welding Process
b. Welding Current
c. Maximum Amperage
d. Primary power connections
e. All of the above
©
14. What is the first step in setting up a SMAW machine?

a. Select electrodes
b. Identify welding current
c. String welding line
d. All of the above
15. When working with electrodes, you should practice which of the following:
a. Replace insulators when damaged.
b. Handle cutting lines with care and keep away from flames.
c. Never leave a rod in the holder unattended.
d. Never lay a rod down near a torch.
e. A and B only
f. All of the above
©
Directions: Introduce the topics and objectives for Lesson 4 (p. 85, Slide 58).
SMAW Electrodes
• Recognize and
select electrodes
• Identify electrodes
based on code
classifications
• Determine
applications of low
hydrogen electrode
groups
• Handle and store
electrodes according
to procedures
58
Slide 58
©
Tack Welding Instructor’s Guide Lesson 4—SMAW Electrodes
Lesson 4—SMAW Electrodes
Lesson Overview
In this lesson, you'll learn to make correct
electrode selections when using SMAW to
tack weld. How to identify different types of
filler metals along with proper storage
methods will be reviewed. You will also
practice selecting the electrodes needed for
an assigned welding task.

After completing the SMAW Electrodes lesson, participants will be able to:
Recognize common electrodes used for tack welding and their role in the
welding process
Select electrodes appropriate for a specific tack weld project
Identify electrodes based on code classifications
Determine the best applications of low hydrogen electrode groups
Handle and store electrodes according to procedures
©
Lesson 4 – Part 1
Topic Page/Slide #
SMAW Electrodes 86, Slides 59
Electrode Flux 87, Slide 60
Common Electrodes for Tack Welding 89
Lab 13: Tack Welding Demonstration 88, Slide 61
Electrode Classification 90, Slide 62
Activity 5: Electrode Classification System 91, Slide 63
Electrode Groups 92, Slide 64
Electrode Selection 93, Slide 65
Activity 6: Testing for Base Metal and Electrode 81, Slide 66
Compatibility Demonstration
Electrode Storage and Handling 95-96, Slide 67
Lab 14: Low-Hydrogen Electrode Demonstration 97, Slide 68
Quiz: SMAW Electrodes 98-99, Slide 69
Instructor Note: Have an assortment of electrodes, including 7018 and

6011, on display for discussion and Activity 5. If available,
have some examples of damaged electrodes and poor tack
welds that were the result of damaged electrodes on
display. Have a portable electrode storage container on
display if available. Set up a welding booth in preparation
for completion of Labs 13, Lab 14, and Activity 6. Have
scrap metal available for completion of Activity 6.
SMAW Electrodes. Explain that in arc welding, electrodes

SMAW Electrodes
• Consumable
are used to conduct current through a workpiece to fuse two
electrodes melt into
the weld joint and
become part of the
pieces together (p. 86, Slide 59). Note that in the SMAW
initial weld.
welding process, the electrode is a consumable which
means that it melts into the weld joint and becomes part of
59
the joint (p. 86, Slide 59).
Slide 59 Remind learners that SMAW is also referred to as stick
welding, which refers to the electrodes. Note that knowing
how to handle and store electrodes properly is important.
©
Electrode Flux. Note that electrodes have a metal core with

Electrode Flux
• SMAW electrodes have a metal core with a
a flux coating (p. 87, Slide 60). Explain that the flux shields
flux coating.
– Flux—shields the weld the weld and the wire core transfers the current to the
material. Explain that the flux helps to eliminate undesirable
– Wire core—transfers the current to the material.
substances from the welds.

Examples of spatter and slag
Review the bulleted list which outlines the functions of

60
Slide 60 melted flux (p. 87).
Complete Lab 13: Tack Welding Demonstration (p. 88, Slide

• Observe how to use electrodes to tack
61). Be sure to wear appropriate PPE and following safety
weld.
guidelines.
Common Electrodes for Tack Welding. Note that there

61
are a variety of low-hydrogen rods in different diameters,
however, en try-level shipfitters will work with E6011 and
Slide 61
E7018 (p. 89).
Electrode Classification. Explain the classification of

Electrode Classification
electrodes (p. 90, Slide 62). Show learners where the
E 60 1 1
specification numbers are found o n the electrode.
Electr ode Tensile Welding Position Flux
Str ength (All pos itions ) Ty pe &
Curre nt
Know how the lettering and numbering works

when selecting electrodes for tack welding.
62
Slide 62
Complete Activity 5: Electrode Classification System (p. 91,

Slide 63).
• Activity 6: Watch how to test for base
metal and electrode compatibility.
66
Slide 63
Electrode Groups. Review the standard sizes of

Electrode Groups electrodes—3/32” to 1/ 4” (p. 92, Slide 64). Remind learners
that amperage application for electrodes is proportionate to
the diameter of the electrode. Also note that electrode
lengths vary according to the manufacturer.
64
Explain that electrodes are grouped based on general

Slide 64 characteristics. Note that the low-hydrogen electrode is the
most common to tack welding.
©
Electrode Selection. Review the list of considerations

Electrode Selection
regarding electrode selection (p. 93, Slide 65).
65
Slide 65
Complete Activity 6: Testing for Base Metal and Electrode

Electrode Classification Compatibility Demonstration (p. 91, Slide 66).
• Activity 5: Locate the classification of
each electrode and describe what each
number and letter represents.
63
Slide 66
Electrode Storage and Handling. Note that electrodes can

Electrode Storage & Handling
• Store filler metal in
be damaged due to improper handling and storage (p. 95,
Slide 67). Note further that welding with damaged
warm, dry area away
from floor.
• Place them to avoid
possible damage.
• Put electrodes in oven if
electrodes can result in defective welds. Show learners
examples of damaged electrodes and faulty welds.
containers have been
opened.
67
Note that electrodes must be kept dry. Note that low-

Slide 67
hydrogen electrodes absorb moisture very quickly, which
result in faulty welds. Explain that rods should be stored in a
rod oven at 250° according to AWS standards. Show
students a rod oven.
Review list of storage rules for electrodes (p. 95, Slide 67).
Mention that every shipyard has different procedures for

handling and storing electrodes (p. 96). Explain that low-
hydrogen electrodes will b shipped in specially sealed
containers, pleased in special ovens and follow a series of
draying and redrying cycles.
Complete Lab 14: Low-Hydrogen Electrode Demonstration

Lab 14: Low Hydrogen Demo
• Observe how a low hydrogen E7018 (p. 97, Slide 68).
electrode works when tack welding.
68
Slide 68
©

the SMAW Electrodes quiz (pp. 98-99, Slide 69). Review
SMAW Electrodes Quiz results with class.
69
Slide 69
©

Directions: Your instructor will demonstrate how to perform a tack weld while explaining
the part an electrode plays in the process. Listen and observe. Ask questions for
clarity. Later when practicing tack welding, you will have many opportunties to see this
process in action for yourself.
NOTES
associated with tack welding as well as the guidelines for
proper handling of electrodes. Be sure to explain the role that
the electrode plays in the welding process. Involve
participants as much as possible in the demonstration. Be
sure to complete an extensive question and answer session.
©
Activity 5: Electrode Classification System
Directions: Your instructor will provide you with a variety of electrodes. Examine the
various shapes and sizes of each. Locate the classification system on each electrode
and describe what each number/letter represents in the space below.
Instructor Note: Check the work of participants as they complete this activity.
Have them share their answers with the group and explain
their findings. Give feedback and make corrections as
needed.
©
Activity 6: Testing for Base Metal and Electrode

Directions: Your instructor will demonstrate how to test for base metal and electrode
compatibility. Observe the process and prepare to discuss your observations.
Follow these simple steps to conduct your own assessment of base metal and electrode
compatibility:
1. Use the base metal to fit a “T-Joint” together.

2. Make a short weld on one side of the T-Joint.
3. Let the weld cool.
4. Break the vertical section of the T-Joint on the opposite side of the weld.
5. Inspect the weld for proper penetration.
proper handling of electrodes. Explain in detail as you
demonstrate. After your initial demonstration, demo again
and have random participants explain back to the group how
to test for base metal and electrode compatibility.
©
Lab 14: Low-Hydrogen Electrode Demonstration

Directions: Watch as your instructor demonstrates how a low-hydrogen E7018
electrode works when tack welding. Ask questions for clarity. You will begin practice
with these electrodes shortly.
NOTES
proper handling of electrodes. Have learners determine
amperage. Explain in detail as you demonstrate. Involve
©
Quiz: SMAW Electrodes

PG (pp. 98-99, Slide 69).
SMAW Electrodes Quiz

69
Slide 69
©
Quiz: SMAW Electrodes

Directions: Circle the best answer for each question or statement.
1. True or False: Upon completion of a tack weld, if it breaks when tested, this
means the electrode and material welded are not compatible.
a. True
b. False
2. The third or fourth digit in the electrode classification represents what?

a. Welding position
b. Tensile strength
c. E for “electrode” or “electricity”
3. SMAW electrodes must be kept warm and dry for what reasons?
a. They disintegrate if left in the open for too long
b. They are magnetic and collect dirt and dust easily
c. They absorb moisture easily
d. All of the above
4. If electrode handling and storage procedures are ever in question, what should
you do?
a. Read the shipyard procedures for handling electrodes and make a
decision about what to do
b. Seek the advice of your supervisor
c. Do nothing
5. True or False: The last digit in the electrode classification E7018 indicates flux
type and current.
a. True
b. False
6. Which of the following should you take into account when selecting electrodes for
tack welding?
a. Identify metal thickness—use electrode smaller in diameter than metal
thickness being welded
b. Identify metal welding position
c. Identify the joint design
d. Identify welding machine
e. a, b, and c
©
7. The first two (2) digits of the electrode classification E7018 indicate what about
the electrode
a. Welding position
b. Tensile strength
c. Flux type and current
8. True or False: The “low-hydrogen” electrode is used the least when tack welding
a. False
b. True
9. In SMAW, the electrode is ________________.

a. Nonconsumable
b. Consumable
c. Both nonconsumable and consumable depending on the type of electrode
being used
10. What is NOT a purpose of the electrode flux?

a. Cleans and deoxidizes the molten metal
b. Serves as a stabilizer for the arc and reduces spatter
c. Produces slag over the weld that allows for a slower cooling rate
d. Provides an oxygen shield from atmospheric gases
©
Tack Welding Instructor’s Guide Lesson 5—SMAW Techniques
SMAW Techniques
• Setup SMAW
equipment
• Strike an arc
• Tack weld using

6011 and 7018
electrodes
70
Slide 70
©
Lesson 5—SMAW Techniques
Lesson Overview
In this lesson, you'll learn the basic
techniques for performing tack
welds using SMAW. Work
positions will be demonstrated and
standard procedures will be
explained including striking an arc.
As a part of this lesson, you will
begin extensive practice creating
tack welds using various
electrodes and steels.

After completing the SMAW Techniques lesson, participants will be able to:
Set up SMAW equipment for tack welding
Strike an arc for tack welding
Tack weld in various positions using 6010 and 7018 electrodes
Recognize the characteristics of good and bad tack welds
©
Lesson 5 – Part 1
Topic Page/Slide #
Weld Coupons 101, Slide 71
Preparing Test Coupons 103, Slide 72
Activity 7: Weld Coupons 104, Slide 73
Lab 15: Tack Welding Demo 105, Slide 74
Instructor Note: Have weld coupon samples available for Activity 7. Have
welding booth set up for completion of Lab 15.
Weld Coupons. Explain to learners that they will practice

Weld Coupons welding on test coupons (p. 102, Slide 71). Note that
different types of weld coupons are designed to allow
practice on different tack welds and experience working with
various metal types and thicknesses. Explain that students
71
will be using coupons to strike an arc, run beads, and
overlap beads.
Slide 71
Refer students to the illustration outlining material costs (p.
102). Note that steel is expensive and encourage learners to
reuse weld coupons as much as possible.
Preparing Test Coupons. Remind learners that tack

welding is the first pass of piecing parts together so that final
welds can be performed effectively. Note that when tacking
two parts together, about a 1/2” bead is used and the joints
are tacked on both sides.
Explain that the key to tack welding is to made short, clean,

Preparing Test Coupons
solid welds that produce parts that are accurately aligned for
further welding (p. 103, Slide 72).
1. Use hand tool to realign
workpieces on the sides
and ends
2. Tack the far ends of
workpieces
3. Make intermediate tack
welds as needed to
maintain workpiece
alignment
Have students to prepare weld coupons using a wire brush,
72
grinder, or other cleaning tool for use in Lab 15.
Slide 72 Review the key first steps to follow when tack welding (p.
103).
©
Complete Activity 7: Weld Coupons (p. 104, Slide 73).

• Activity 7: Observe and listen to

information about different weld coupons.
73
Slide 73
Complete Lab 15: Tack Welding Demonstration (p. 105,

Slide 74).
• Observe how the first steps of tack
welding are performed.
74
Slide 74
©
Activity 7: Weld Coupons

Directions: Your instructor will provide you with samples of weld coupons. Examine
them and listen to the key points provided about the uses of each. You will later have a
chance to create some for your own for practice work.
NOTES
Instructor Note: Mix and mingle among the participants as you describe the
weld coupons.
©
Directions: Watch as your instructor demonstrates the first steps of tack welding.
Listen and observe in preparation for you own applications of these techniques. Make
notes below and ask questions for clarity.
NOTES
amperage. Explain in detail as you demonstrate. Involve
©
Lesson 5 – Part 2
Topic Page/Slide #
SMAW Components 106, Slide 75
Typical Stick Welding Setup 107-108, Slide 76
Lab 16: Setup of SMAW Equipment 109, Slide 77
Instructor Note: Have a power source and other components available for
review of SMAW components and stick welding setup
demonstration.
SMAW Components. Review SMAW components on a

SMAW Components
• Find the following:
welding machine or refer learners to illustration on p. 106
– Stick welding
power source (Slide 75). Review the function of each component in the
– Insulated
electrode holder
– Workpiece SMAW process.
– Ground clamp
75
Slide 75
Typical Stick Welding Setup. Demonstrate the setup for

Stick Welding Setup
stick welding (pp. 107-108, Slide 76). Remind learners that
in order for the welding current to start, the electrode must
• Follow steps 1-7
in PG for simple
setup.
touch the workpiece.
76
Slide 76
Complete Lab 16: Setup of SMAW Equipment (p. 109, Slide

Lab 16: Setup Equipment
• Observe how to setup SMAW equipment:
77).
– Workpiece
– Work clamp
– Electrode holder
Answer the questions in your PG.
77
Slide 77
©
Lab 16: Setup of SMAW Equipment

Directions: Watch as your instructor demonstrates the general setup of the following
SMAW equipment:
Workpiece
Work Clamp
Electrode Holder
Answer the following questions:
1) What type of preparation needs to be done to the workpiece to render a quality

tack weld?
2) What purpose does the work clamp serve and what happens if the work clamp is
not properly located?
Instructor Note: Review the answers to these questions by having participants

share their responses. Provide feedback and additional
information as needed.
©
Lesson 5 – Part 3
Topic Page/Slide #
Striking an Arc 110, Slide 78
 Scratch Start Technique 111, Slide 79
 Tapping Technique 112, Slide 80
 Lab 17: Striking an Arc 113, Slide 81
Instructor Note: Have a power source and other components—electrode

holder (whip), workpiece, ground clamp—in addition to
electrodes available for review of SMAW components and
stick welding setup demonstration.
Striking an Arc. Remind learners that when welding, an

Striking an Arc arc is produced at the end of the electrode which melts the
metal core, the flux coating, and the base metal (p. 110,
• Two Techniques:
– Scratch start
Slide 78). Note that the temperature exceeds 6,000°F.
Explain that the welds are primarily formed when the wire
– Tapping
78
core mixes with the melted base metal.
Slide 78 Introduce the two techniques for striking an arc—the scratch
start and tapping methods (p. 110, Slide 78).
Scratch Start Technique. Describe how to strike an arc

Scratch Start Technique using the scratch start technique, dragging the electrode
across the workpiece like striking a match and immediately
• Remember:
– Welding current lifting the electrode slightly after touching the workpiece (p.
starts as soon as
you touch the
workpiece Part 1—Electrode
111, Slide 79). Note that if the arc goes out, the electrode
was lifted too high and if the electrode sticks to the
Part 2—Workpiec e
Part 3—Arc
79
workpiece, quickly twist it to free it. Note, too, that the

Slide 79
scratch start technique is the preferred technique for arc
welding.
Tapping Technique. Describe how to strike an arc using

Tapping Technique
the tapping technique, bringing electrode straight down to
• Bring electrode
the workpiece, then lift it slightly to start the arc (p. 112,
Slide 80). Note that as with the scratch start method, lifting
straight down to
workpiece
• Lift slightly
Part 1—Electrode
Part 2—Workpiec e
the electrode too high will cause the arc to go out and if the
Part 3—Arc
80
electrode sticks to the workpiece, a quick twist will free it.
Slide 80
©
Remind learners that the welding current will not start until
the electrode touches the workpiece.
Complete Lab 17: Striking an Arc (p. 113, Slide 81).

Lab 17: Striking an Arc
• Observe how to strike an arc:
– Scratch start technique
– Tapping technique
81
Slide 81
©
Lab 17: Striking an Arc

Directions: Watch as your instructor demonstrates striking an arc using the tapping and
scratch start techniques. Ask questions for clarity. Listen and observe carefully and
prepare to practice using both techniques to strike an arc.
Practice striking an arc is a good opportunity to continue getting comfortable

wearing your PPE and applying your skills at safely handling SMAW
equipment. Exercise caution and apply all the safety rules reviewed earlier.
amperage. Explain in detail as you demonstrate striking an
arc using both techniques. Involve participants as much as
possible in the demonstration. Observe as learners
demonstrate each technique making sure that they are
wearing appropriate PPE and observing safety practices. Be
sure to complete an extensive question and answer session
at the conclusion of the activity.
©
Lesson 5 – Part 4
Topic Page/Slide #
Positioning Electrode Holder 114-115, Slide 82
Lab 18: Fillet and Groove Tack Welding 116, Slide 83
Demonstration
Electrode Movement during Weld 117, Slide 84
Conditions That Affect Tack Weld Bead Shape 118, Slide 85
Poor Weld Bead Characteristics 119, Slide 86
Good Weld Bead Characteristics 120, Slide 87
Lab 19: Good and Bad Tack Weld Demonstration 121, Slide 88
Instructor Note: Have a power source and other components—electrode

holder (whip), workpiece, ground clamp—in addition to
electrodes available for discussion and demonstration. Have
examples of poor weld beads and good weld beads.
Positioning Electrode Holder. Use the display model and

Positioning Electrode Holder
• For best results:
reference the illustrations (p. 115) to show students how to
– Hold a short arc
– Travel at uniform speed position the electrode holder (almost perpendicular to
surface) for groove and fillet welds (p. 114-115, Slide 82).
– Feed electrode downward at constant rate
Note that tilting the electrode holder in the direction of travel

Groove Welds Fillet Welds
82
is helpful.
Slide 82
Complete Lab 18: Fillet and Groove Tack Welding

Lab 18:Fillet Welding Demo
• Observe the techniques of fillet and
Demonstration (p. 116, Slide 83).
groove tack welding.
83
Slide 83
Electrode Movement During Weld. Using the display

Electrode Movement
1. Stringer Bead
welding machine, introduce stringer bead, weave bead, and
2. Weave Bead
3. Weave Patterns weave patterns, referring learners to illustration and
demonstrating in class (p. 117, Slide 84). Note that for
groove weld joints, a single stringer bead is sufficient;
84
however, for wide groove weld joints or bridging across gaps
Slide 84 a weave bead or multiple stringer bead works better.
©
Conditions that Affect Tack Weld Bead Shape. Refer

Conditions Affecting Beads
1. Electrode Angle learners to illustration (p. 118, Slide 85). Note the factors
that affect weld bead shape—arc length, travel, speed,
2. Arc Length thickness of metal.
3. Travel Speed
85
Slide 85
Poor Weld Bead Characteristics. Referring learners to

Poor Weld Beads
1. Large spatter deposits
illustration, review the characteristics of a poor weld bead—
2.
3.
Rough, uneven bead
Slight crater during welding large spatter deposits, rough, uneven bead, slight crater
during welding, bad overlap, poor penetration (p. 119, Slide
4. Bad overlap
5. Poor penetration
86). Show learners examples of poor weld bead

Examples of poor t ack welds.
86
characteristics and discuss possible factors that led to
Slide 86 defective welds.
Good Weld Bead Characteristics. Review the

Good Weld Beads characteristics of a good weld bead—fine spatter, uniform
1. Fine spatter
2. Uniform bead
3. Moderate crater during
bead, moderate crater during welding, no overlap, good
penetration into base metal, referring learners to illustration
welding
4. No overlap
5. Good penetration into
base metal
(p. 120, Slide 87). Show learners examples of good weld
Good tack welds
bead characteristics and discuss.
87
Slide 87
Complete Lab 19: Good and Bad Tack Weld Demonstration

Lab 19: Good and Bad Demo
• Observe the differences between good
(p. 121, Slide 88).
and bad tack welds.
88
Slide 88
©
Lab 18: Fillet and Groove Tack Welding

Demonstration
Directions: Watch as your instructor demonstrates the techniques for fillet tack welding.
Ask questions for clarity. Listen and observe carefully and prepare to practice using
both techniques to create effective tack welds.
amperage.
Explain in detail as you demonstrate positioning the electrode

holder and electrode movement during the weld. Involve
©
Lab 19: Good and Bad Tack Weld Demonstration

Directions: Watch as your instructor demonstrates the contrast between good tack weld
and bad tack welds. S/he will also explain what to do or not do to be effective. Ask
questions for clarity. Listen and observe carefully in preparation for practicing your own
tack welding techniques.
amperage. Note the position of the electrode holder and
electrode movement during the weld.
Demonstrate techniques that lead to faulty welds as well as

the proper techniques for good tack welds. Have learners
identify which ones are good and which ones are bad and
explain what made each weld good or bad. Involve
©
Lesson 5 – Part 5
Topic Page/Slide #
Welding Coupon Test 122, Slide 89
Lab 20: Creating Tack Welds 116, Slide 90
Quiz: SMAW Electrodes 98-99, Slide 91
Instructor Note: Have several coupons that have been tack welded with
good beads and defective beads, a hammer, and vice to
demonstrate how to test tack welds.
Welding Coupon Test. Review the steps to follow to test a

Welding Coupon Test
• Strike weld joint in the direction shown welding coupon (p. 122, Slide 89). Refer learners to
illustration (p. 122) and discuss before demonstrating
• When test coupon breaks, weld will be
examined for proper penetration and tie-
ins
procedure. Note that the weld should be examined for

proper penetration and tie-ins. Review the list of factors that
89
could lead to faulty welds (p. 122).
Slide 89
Perform tests on the display coupons and evaluate each
weld. For defective welds, note possible causes. Allow
learners in groups to perform the test, evaluate the welds,
and discuss with the class.
Complete Lab 20: Creating Tack Welds (p. 116, Slide 90).
Lab 20: Creating Tack Welds
• Integrate your skills!
90
Slide 90

the SMAW Electrodes quiz (pp. 98-99, Slide 91). Review
SMAW Techniques Quiz results with class.
91
Slide 91
©
Lab 20: Creating Tack Welds

Directions: In this lab you will begin integrating all the skills and knowledge you have
learned so far on how to create tack welds. Your instructor will provide you with several
different electrodes and weld coupons. This practice session will involve repetitive
practice of tack welding techniques to test for effective penetration.
Follow the procedures given and begin practicing tack welding in the positions
assigned. Your instructor will provide you with ongoing coaching and feedback. As a
part of this practice, you will be critiqued for adherence to safety practices.
REMEMBER! Always wear required PPE and adhere to the guidelines for
safe welding.
Instructor Note: Watch for the application of comprehensive learning in this

lab. Participants should be able to tack weld accurately
using the positions and weld types you assign them wearing
appropriate PPE and following safety guidelines covered in
this course.
Have learners test coupons, evaluate welds, and explain

causes of defective welds.
Give them ongoing feedback during and after their

performance.
©
Quiz: SMAW Techniques

PG (pp. 124-125, Slide 91).
SMAW Techniques Quiz

91
Slide 91
©
Quiz: SMAW Techniques

Directions: Circle the best answer for each question or statement.
1. What is the first step in tack welding?

a. Realign workpieces on the sides and ends
b. Tack the far ends of the workpiece
c. Make immediate tack welds as necessary
2. An insulated electrode holder is also called a ________________.

a. Rod
b. Clamp
c. Whip
d. Stick
3. True or False: Small diameter electrodes require more amperage than large
ones.
a. True
b. False
4. Which of the following is the best definition for arc length?

a. The shortest distance from the electrode to the workpiece
b. The distance from the electrode to the workpiece
c. The amount of current flowing into the workpiece.
d. All of the above
5. True or False: Remove slag and check weld bead before making another weld
pass.
a. True
b. False
6. When striking an arc, which of the following would you NOT do?
a. Drag electrode across workpiece like striking a match
b. Immediately lift electrode slightly after touching work
c. If arc goes out, shake the electrode in the air to get the arc back
d. If electrode sticks to workpiece, use a quick twist to free it
7. True or False: To produce the best results when tack welding, hold a short arc,
travel at a uniform speed, and feed the electrode downward at a constant rate as
it melts.
a. True
b. False
©
8. What items below have an effect on tack weld bead shape?

a. Electrode angle, arc length, travel speed & thickness of base metal
b. Electrode angle, arc penetration, travel speed & thickness of base metal
c. Electrode direction, arc length, travel speed & thickness of base metal
9. This does NOT qualify as a characteristic of a poor weld bead.

a. Large spatter deposits
b. Rough uneven bead
c. Good penetration
d. Slight crater during welding
10. This does NOT qualify as a characteristic of a good weld bead.

b. Uniform bead
c. Good penetration
d. Bad overlap
©
Tack Welding Instructor’s Guide Summary and Assessment
Summary and Assessment
Instructor Note: Review the key learning points from this module.
Consider the following accelerated learning activity for
summarizing course information:
Have learners stand up and find a partner.

Have them talk for 15 seconds about something they learned in the course.
Have them change partners after 15 seconds and tell another partner something
they learned.
Continue these 15 second sharing sessions for about 1-2 minutes.
Ask various participants to share a key takeaway they have from the training.
This serves as a reminder and quick review of the content covered.
Summary
Tack Welding Safety Tack Welding Basics SMAW Equipment
SMAW Electrodes SMAW Techniques

92
Slide 92
Tack Welding Application

Assessment
Test Your Skills & Knowledge!
93
Slide 93
©
Final Assessment: Tack Welding

1. True or False: In tack welding, goggles can be used for protection instead of
welding shields.
a. True
b. False
2. Which of the following hazards are associated with welding:

a. Electric Shock
b. Fumes and Gases
c. Arc Rays
d. Fire or Explosion
e. All of the Above
3. True or False: Welding hoods should be fitted with the proper shade of filtered lens
to protect your face and eyes when tack welding.
a. True
b. False
4. Of the PPE listed below, which is NOT required for welding?

a. Cuffed pants
b. High top, steel toed boots of at least 6”
c. Earplugs
d. Welding shields and tight fitting welding goggles over safety glasses
5. When welding, how should flammables located within 35 ft. of the welding arc be
handled?
a. Remove flammables if possible
b. Cover flammables that can’t be moved with approved covers
c. Both a and b
d. Neither a nor b
6. Welding, chipping, wire brushing, and grinding cause sparks and flying metal. As
welds cool, they can throw off slag. To protect yourself from injury you should:
a. Always wait until the weld cools to chip or grind
b. Wear approved safety glasses with side shields even under your
welding helmet.
c. Never grind or use a wire brush
7. True or False: Electric arcs should never be viewed directly or indirectly with the
naked eye.
a. True
b. False
©
8. Clamp work cable with good metal-to-metal contact to ground or to worktable as

near the weld as practical in order to _______________________________.
a. Provide proper insulation
b. Avoid an unstable work area
c. Prevent electric shock
9. What are some factors that lead to hazardous work conditions?

a. Mental or physical stress
b. Medications, illness or injury
c. Age and inexperience
d. Alcohol or illegal drug use
e. All of the above
10. Welding can cause fire or explosion. What are some things you do to prevent this
from happening?
a. Wear oil-free protective garments such as leather gloves, heavy shirt,
cuffless trousers, high shoes, and a cap.
b. Remove any combustibles, such as a butane lighters or matches, from
your person before doing any welding.
c. Remove stick electrode from holder or cut off welding wire at contact tip
when not in use.
d. Both A and C
e. All of the above
11. True or False: Tack welding actually is welding; it is just a short weld.
a. True
b. False
12. True or False: The American Welding Society publishes standards of performance
for tack welders.
a. True
b. False
13. True or False: The primary types of welds that tack welders work with are fillet and
groove.
a. True
b. False
14. True or False: Upon completion of a tack weld, if it breaks when tested, this means
the electrode and material welded are not compatible.
a. True
b. False
©
15. True or False: When metal deposits form a uniform layer during tack welding, it is
called a bead.
a. True
b. False
16. The structural components and shapes most commonly used in shipfitting include
the following:
a. Channel, Pipe, H-Beam, I-Beam, Tee Bar and Eyebolt
b. I-Beam, H-Beam, Tee Bar, Angle, Channel, Square Tubing & Flat
Bar
c. Angle, Channel, Pipe, H-Beam, I-Beam, Tee Bar & Flat Bar
17. A fillet plate weld in a vertical position would be identified as:

a. 1F
b. 2F
c. 3F
d. 4F
18. A fillet weld in a horizontal position would be identified as:

a. 1F
b. 2F
c. 3F
d. 4F
19. A groove weld in a flat position would be identified as:

a. 1G
b. 2G
c. 3G
d. 4G
20. A groove weld in an overhead position would be identified as:

a. 1G
b. 2G
c. 3G
d. 4G
21. For the following illustration, identify the type of joint and welding position:
a. Lap joint in the flat position
b. Groove joint in the vertical position
c. Tee joint in the overhead position
d. Tee joint in the horizontal position
©
a. Lap joint in the horizontal position

b. Groove joint in the flat position
c. Lap joint in the vertical position
d. Groove joint in the horizontal position
a. Lap joint in the horizontal position
b. Groove joint in the flat position
c. Tee joint in the overhead position
d. Groove joint in the vertical position
24. From the following list, which is considered a structural member commonly used by
shipfitters:
a. I-Beam
b. Angle
c. Channel
d. H-Beam
e. All of the above
25. The structural member below is called a/an

a. I-Beam
b. T-bar
c. Channel
d. H-Beam
26. The structural member below is called a/an

a. I-Beam
b. T-bar
c. Channel
d. H-Beam
27. Structural members have common identifiers. On the I-beam below, the area
identified by the arrows is called the:
a. Flange
b. Fillet
c. Bosom
d. Toe
28. True or False: Tack welding helps prevent butt joint distortion by tacking the
©
materials in position before the final weld.

a. True
b. False
29. True or False: Tack welding helps prevent butt joint distortion by tacking the
materials in position before the final weld.
a. True
b. False
30. If a tack weld of 3/16” is required, a 7/16” tack weld will create an oversized tack.
Will this allow the final welder to weld to specification?
a. Yes
b. No
c. Not enough information
31. After each weld pass, what should be done?

a. Grind surface smooth
b. Spray the weld off with water
c. Surfaces should be thoroughly cleaned before starting a new tack
weld
d. Nothing, move on to the next tack weld
32. Below is an example of a bad stick weld. What is most likely the cause?
a. Travel too fast
b. Travel too slow
c. Amperage to high
d. Arc to short
e. Arc to long
33. Below is another example of a bad stick weld. What is most likely the cause?
a. Travel too fast
b. Travel too slow
c. Amperage to high
d. Arc to short
e. Arc to long
34. True or False: The longer the distance a welding cable has to get to the workpiece,
the less heat that is produced.
a. True
b. False
35. The electrical disconnect for a welding machine should be identified before hookup
and use so that in an emergency the power source can be quickly disabled.
a. True
b. False
©
36. Shielded Metal Arc Welding (SMAW) is also called _______________ welding.
a. Stick
b. Rod
c. Electrode
d. Hot
37. On the diagram of the welding circuit below, the arrows (a) and (b) are pointing to
what parts?
On
(b)
Off
+ -
(a)
a. Ground Lead and electrode lead

b. Power source and electrode holder
c. Workpiece and electrode lead
d. Electrode holder and ground lead
38. True or False: When using the SMAW process to weld, the electrical circuit is NOT
closed until the electrode touches the workpiece.
a. True
b. False
39. What is the primary material used when performing Shielded Metal Arc Welding?
a. Flux
b. Electrode
c. Bead
d. Low Hydrogen Steel
40. The outer coating on an electrode is called __________.

a. Heavy coating
b. Shield
c. Arc
d. Flux
41. The direction electrical current flows in a direct current welding circuit is called
polarity.
Created for Gulf States Shipbuilders Consortium by The Woodham Group, Inc. 106
42. Which of the following parts are involved in the SMAW process?
a. Stick welding power source
b. Insulated electrode holder (whip)
c. Workpiece
d. Work clamp
e. All of the above
43. What does this international symbol mean?

a. Caution, risk of electric shock
b. Beware, high voltage in area
c. Work safely, shock may occur
44. A smaller electrode and lower amperage is usually needed to tack weld a small
piece as compared to a large piece of the same thickness. Thin metals require less
current than thick metals, and a small electrode requires less amperage than a large
one.
a. True
b. False
45. To select the right SMAW Machine you need to identify which of the following?
a. Welding Process
b. Welding Current
c. Maximum Amperage
d. Primary power connections
e. All of the above
46. When working with electrodes, you should practice which of the following:
a. Replace insulators when damaged.
b. Handle cutting lines with care and keep away from flames.
c. Never leave a rod in the holder unattended.
d. Never lay a rod down near a torch.
e. A and B only
f. All of the above
47. In the electrode classification E6011, the “E” stands for what?
a. Welding position
b. Tensile strength
c. Electrode
©
48. In the electrode classification E7018, the number “1” stands for what?
a. Welding position
b. Tensile strength
c. Electrode
49. True or False: The last digit in the electrode classification E7018 indicates the flux
type and current.
a. True
b. False
50. Electrodes that are not handled and stored properly can lead to faulty welds. SMAW
electrodes must be kept warm and dry for what reasons?
a. They disintegrate if left in the open for too long
b. They are magnetic and collect dirt and dust easily
c. They absorb moisture easily
d. All of the above
51. Which of the following should you take into account when selecting electrodes for
tack welding?
a. Identify metal thickness—use electrode smaller in diameter than metal
thickness being welded
b. Identify metal welding position
c. Identify the joint design
d. Identify welding machine
e. a, b, and c only
52. True or False: The “low-hydrogen” electrode is used the least when tack welding
a. True
b. False
53. In SMAW, the electrode is considered a ________________.

a. Nonconsumable
b. Consumable
c. Both nonconsumable and consumable depending on the type of electrode
being used
54. What is the function of the electrode flux?

a. Shields the weld from atmospheric gases
b. Eliminates oxides and other undesirable substances from the weld
c. Serves as a stabilizer for the arc and reduces spatter
d. Produces slag over the weld that allows for a slower cooling rate
e. All of the above
©
55. When joining two parts together, what is the next step after making the initial tack?
a. Realign workpieces on the sides and ends
b. Tack the far ends of the workpiece
c. Make immediate tack welds as necessary
56. An insulated electrode holder is also called a ________________.

a. Rod
b. Clamp
c. Whip
d. Stick
57. True or False: When stick welding, the welding current starts before the electrode
touches the workpiece.
a. True
b. False
58.True or False: Small diameter electrodes require more amperage than large ones.
a. True
b. False
59. Which of the following is the best definition for arc length?
a. The shortest distance from the electrode to the workpiece
b. The distance from the electrode to the workpiece
c. The amount of current flowing into the workpiece
d. All of the above
60. True or False: Remove slag and check weld bead before making another weld
pass.
a. True
b. False
61. When striking an arc, which of the following would you NOT do?
a. Drag electrode across workpiece like striking a match then immediately lift
it slightly
b. Bring the electrode straight down until it touches the workpiece then lift it
slightly
c. Drag the electrode across the workpiece and letting it remain on the
workpiece
d. Bring the electrode straight down until it touches the workpiece and letting
it remain on the workpiece.
e. Both a and b
f. Both c and d
©
62. True or False: To produce the best results when tack welding, hold a short arc,
travel at a uniform speed, and feed the electrode downward at a constant rate as it
melts.
a. True
b. False
63. What items below have an effect on tack weld bead shape?
a. Electrode angle, arc length, travel speed & thickness of base metal
b. Electrode angle, arc penetration, travel speed & thickness of base metal
c. Electrode direction, arc length, travel speed & thickness of base metal
64. This does NOT qualify as a characteristic of a POOR weld bead.

b. Rough uneven bead
c. Good penetration
d. Slight crater during welding
65. This does NOT qualify as a characteristic of a GOOD weld bead.

b. Uniform bead
c. Good penetration
d. Bad overlap
©
Tack Welding Application Assessment
Directions: Your instructor will give you two pieces of flatbar for each position to be
tested. Each test will be broken and examined for penetration and proper tie-ins. You
must be able to set up the equipment and test plates in the appropriate position(s).
Required PPE must be worn and all safety procedures followed. Your instructor will
inform you when you have successfully completed each test.
©
Tack Welding Instructor’s Guide Course Forms
Competency Rating Form
Instructor Note: Use the Competency Rating Form to document skills

mastered by the individual student and note what skills need
more study/practice. Upon completion, be sure to give a
copy of this rating form to the student, review it with them,
and be prepared to answer any questions they may have.
©
Competency Rating Form
Trainee________________________
Class Tack Welding
Your instructor will use the Trainee Performance Rating Rubric

Competency Rating form to find out P Able to perform task independently
what skills you have mastered and and without error at least 70%
what skills you need more practice on F Unable to perform task, additional
in this module. training needed
Assessment
Lesson Method Performance Date Instructor’s Trainee’s
Competency
Number K=Knowledge Rating Completed Initials Initials
P=Performance
Complete module written
test with a score of at K N/A
N/A
least 70%
Worked safely 100% of
the time. P
N/A
Selected and wore
required PPE. 1 P
Operated safety
equipment and used 1 P
safe work habits.
Adhered to safety signs
and signals in work 1 P
areas.
Setup and operated
SMAW equipment
including leads, cable
connections, stringing 3 P
cable and establishing
ground connections.
Used electrode
classifications to select
electrodes accurately for 4 P
a variety of tack welding
tasks.
Observed welding
procedure specs, metal
thickness, welding
position, joint design,
and welding current 4 P
when selecting
electrodes for tack
welding.
Handled and stored
electrodes safely 4 P
following procedure.
Strike arcs by touching
electrodes to metals
being welded, 5 P
completing electrical
circuits.
Clamped, held, tack-
welded, heat-bent,
ground or bolted
component parts to 3 P
obtain required
configurations and
positions for welding.
Setup and operated
hand and power tools
common to the welding 3 P
trade.
Maintained clean work
areas and weld surfaces 3 P
using hand tools.
Tack welded in flat,
vertical, horizontal and
overhead positions
according to AWS 5 P
standards for Tack
Welders.
Tack welded using a
variety of structural
components and 2 P
shapes.
Produced tack welds
that meet quality 5 P
standards.
Followed quality
standards for producing
good versus bad tack 5 P
welds.
Used and interpreted
tack welding terms
correctly such as rod, 2 P
stick, and electrode.
Detected faulty
operation of equipment
or defective materials 3 P
and notified supervisors.
Tack Welding Instructor Guide Course Forms
TRAINEE SATISFACTION SURVEY
Instructor Note: Upon completion of this module, be sure to have all

participants complete the Trainee Satisfaction Survey. Explain
to them that this survey is an opportunity for them to provide
comprehensive feedback about their experience in this specific
course.
Encourage them to give honest and fair feedback, and remind

them that they are reviewing the course as a whole.
Emphasize that “1” is “strongly disagree” and “5” is strongly
agree”. The higher the score the more they agree with the
statement.
You may need to find out who each participant needs to submit
this survey to since this will vary based on the shipyards and
training partners involved.
Created for Gulf States Shipbuilders Consortium by The Woodham Group, Inc. 115
TRAINEE SATISFACTION SURVEY
Course Title: Tack Welding Course Start Date: ___________________

Instructor Name: ____________________________________ Course Location: ___________________
The major objective of this survey is to improve instruction. Your responses provide valuable feedback and
help form the basis for future course improvements. Because your responses are extremely important to the
improvement process, please respond honestly and fairly. Be sure to consider the course as a whole rather
than focusing on isolated incidents. In the Additional Comments section at the end of the survey, please
explain any rating that was lower than a 4 and tell us what you liked most and least about this course.
Strongly Strongly
Statement
Disagree Agree
Overall Evaluation of Course 1 2 3 4 5 N/A

The course objectives were clear.
The course objectives met my company’s needs.
I met the course objectives.
The course was well organized.
The content of this course was appropriate for me.
My knowledge/skills were increased as a result of this course.
Classroom/lab activities gave me sufficient practice.
The learning objectives for this course were directly related to my job
performance expectations.
The course increased my ability to perform my job.
I will use what I learned in this course on my job.
Instructor 1 2 3 4 5 N/A
The instructor was prepared.
The instructor was knowledgeable of the content he/she was teaching.
The instructor presented the information in a manner easy for me to
understand.
The instructor was effective in explaining the course concepts.
The instructor was able to answer my questions effectively.
The instructor showed interest in my progress.
The instructor created a comfortable yet challenging environment for
positive learning (i.e., pace, interaction, etc.).
Instructional Materials 1 2 3 4 5 N/A

The teaching/learning methods and exercises helped me accomplish
the learning objectives.
The materials used were necessary for my learning.
The materials used were well organized.
The quality of the audio-visual materials was outstanding.
The overall appearance of the training materials aided in my learning.
The print quality of the materials was satisfactory.
The content of the training materials were directly related to the
learning objectives.
Equipment 1 2 3 4 5 N/A
The equipment helped me accomplish the learning objectives.
The equipment was in serviceable condition.
The equipment was clean.
The equipment operated the way it was supposed to.
All of the necessary equipment for the course was available and used.
Facility 1 2 3 4 5 N/A
The facility met my expectations.
The location of the facility was suitable.
The classroom environment was conducive to my training.
The equipment was suitable to meet my learning needs.
The lighting was adequate to meet my learning needs.
The classroom temperature was comfortable.
The restrooms were clean.
The noise level outside the classroom was kept to a minimum.
The room configuration was conducive to my training.
Additional Comments
Please explain any item rated lower than a 4. (Attach additional sheets, if necessary.)
What did you like most about the training?
What did you like least about the training?
Please provide any additional comments that you would like to share.
Tack Welding Instructor’s Guide Course Forms
Shipfitter Participant Guide

Feedback Form
Instructor Note: Upon completion of this module, be sure to use the feedback
form to note any errors you found or ideas you have toward
improving this document based on your experience in teaching
this module.
Direct all participants to complete the feedback form as well,

and collect it before they leave class. These forms can be
submitted by mail, email or fax using the information at the
bottom of the form.
Encourage participants to provide specifics regarding content

that needs to be updated, corrected, added or deleted to
eliminate any errors or inaccuracies. All feedback is important
and will be considered when improving this document for future
training.
©
Shipfitter Participant Guide
Feedback Form
Tell us what you think! It is our goal to continually improve GSSC’s Shipfitter Participant Guide
so that it remains current and error-free. In order to do this, we need your help. Simply
complete the form below if you:
 have an idea for improving the Participant Guide
 find a typographical error
 find an inaccuracy
Module Name Tack Welding Page Number
Suggestion for Improvement Typographical Error Inaccurate Information
Description
Suggested Correction (If Applicable)
Contact Information (Optional)
Name Title
Organization
e-mail Phone ( )
By Mail:  By Fax: By E-mail:

© GSSC 251-809-1677 bdunn@atn.org
2012 Gulf States Shipbuilders Consortium
c/o Alabama Technology Network 119
1110 Montlimar Drive, Suite 200
Mobile, AL 36609

Tack Welding Instructor Guide

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Instructor Guide Contents

Preparing to Teach .................................................................................. 3

Tack Welding Answer Guide................................................................... 8

Lesson 1—Tack Welding Safety ........................................................... 12

Lesson 2—Tack Welding Basics .......................................................... 26

Lab 6: Structural Components..................................................... 40

Lesson 3—Shielded Metal Arc Welding (SMAW) Equipment ............. 45

Lesson 4—SMAW Electrodes ............................................................... 68

Lesson 5—SMAW Techniques ............................................................. 81

Quiz: SMAW Techniques ............................................................. 97

 Scheduling: A comprehensive schedule (ALL courses) is provided

1. About the Module (Opening)—Who are you? Where am I? What is this

1. Practice safety regulations established for SMAW procedures

Tack Welding Answer Guide

The following directions/answers correlate with the activities in this course.

Presentation Activity—Course Benefits

How would an entry-level shipfitter benefit from

Tack Welding Safety

• Wear correct PPE

Lesson 1—Tack Welding Safety

Lesson Learning Objectives

Directions: Discuss the following topics from the Participant Guide:

Topic Participant Guide Page

Instructor Note: Have a set of PPE available for demonstration/completion of

What’s the Difference?

Review the factors that lead to hazardous conditions (p. 8,

• Medications, illness • Hurried shift

• Alcohol and drug • Faulty or

PPE Illustration. Refer learners to image (p. 9, Slide 8).

Personal Protective Equipment (PPE). Review

Ask learners to complete Lab 1: Wearing Personal

Ask learners to complete Activity 1: Observe Tack Welding

Lab 1: Wearing Personal Protective Equipment

Take notes below.

Activity 1: Observe Tack Welding

Take notes below.

Directions: Discuss the following topics from the Participant Guide:

Topic Participant Guide Page

 Electric Shock Can Kill (pp. 14-15)

Ask learners to complete Activity 2: Welding Accidents

Insert (wel ding) Photo Here

Chemical Safety Board’s Dangers of Hot Work

Complete Lab 2: SMAW Tack Welding (p. 24, Slide 13).

Review the key learning points and ask learners to complete

Have students complete the Application Assessment: PPE

Activity 2: Welding Accidents Video

2) What led to the unsafe situation?

3) How could the people involved have worked more safely?

Lab 2: SMAW Tack Welding

Quiz: Tack Welding Safety

Tack Welding Safety Quiz

Test Your Knowledge!

Quiz: Tack Welding Safety

Directions: Circle the correct answer for each question or statement.

5. Do not block or filter airflow to welding unit because it will ____________________.

8. Clamp work cable with good metal-to-metal contact to ground or to worktable as

9. What are some factors that lead to hazardous work conditions?

Application Assessment: PPE

Instructor Note: Allow extensive question and answer sessions to ensure

Watch and observe closely to ensure learning is occurring

Guide learners in correcting each other.

Optional: Provide a piece of PPE that is faulty in some way

Tack Welding Basics

• Identify tack weld