Fabrication and Welding
Level 2
Title:
Fillet welds
Level:
Level 2
Time allowed:
60 minutes
Given:
equipment to
Personal protective equipment, all consumables, tools and
complete the task.
Task:
Weld three tee joints in low carbon steel.
Notes:
Wear all necessary personal protective equipment. Complete the
welding task in a safe manner, with due consideration for your own
safety and the safety of others.
Select consumables appropriate to the task and set up process
parameters appropriate to the welding process.
Set up joints correctly in preparation for welding. Weld all three joints
within the time allocation. All welds must have stop/start at least
50mm from each end of the joint. All three welds to be done in the
PB (horizontal / vertical) position.
Use one of the following processes to weld all three joints


Manual metal arc (111)
Metal active gas shielded process (135)
The diagram below provides additional guidance.
Marking:
Aspects of task
Mark
Joint 1: 3mm thick low carbon steel 200mm long single
run with a leg length no less than 3mm and no greater
than 5mm
10
Joint 2 6mm thick low carbon steel 200mm long single run
with a leg length no less than 6mm and no greater than
8mm
10
Joint 3 6mm thick low carbon steel 200mm long multi run
with a leg length no less than 10mm and no greater than
12mm
10
1
Total marks 30
Competition:
Fillet welds
Competitor:
Date:
Possible
mark
Joint 1: 3mm thick low carbon steel 200mm long single run with a leg length no
less than 3mm and no greater than 5mm
Surface slag, spatter and smoke residue has been removed from 95% of the joint
1
Welded joint is free from stray arc strikes: 1 strike = 1 defect 1 defect = 0.8 marks,
2 defects = 0.5 marks, 3 or more = 0 marks
Joint is set up with the vertical plate on the centre line of the horizontal plate: (allow
no more than 2mm variation)
Stop/starts are smooth on the capping run/s:
(allow 1.5mm variation)
Joint completely fused into the parent material: (no overlap/cold lap)
1
Weld metal is free from surface porosity or inclusions:
1 pore = 1 defect 1 defect = 0.8 marks., 2 defects = 0.5 marks, 3 or more = 0
marks
Welded joint is free from undercut no greater than 0.5mm or equal to 10mm long =
1 defect (accumulative) 1 defect = 0.8 marks, 2 defects = 0.5 marks, 3 or more = 0
marks
Weld is free from excessive face concavity or convexity: (greater than 2mm from
the flat)
Fillet weld leg lengths are in accordance with specification:
1 defect = equal to10mm long (accumulative)
1 defect = 0.8 marks, 2 defects = 0.5 marks, 3 or more defects = 0 marks
Welded joint is complete: fully formed welds may not begin or terminate greater
than 3 mm from the ends of the plate
Joint 2 6mm thick low carbon steel 200mm long single run with a leg length no less
than 6mm and no greater than 8mm
Surface slag, spatter and smoke residue has been removed from 95% of the joint
1
Welded joint is free from stray arc strikes: 1 strike = 1 defect 1 defect = 0.8 marks,
2 defects = 0.5 marks, 3 or more = 0 marks
Joint is set up with the vertical plate on the centre line of the horizontal plate: (allow
no more than 2mm variation)
Stop/starts are smooth on the capping run/s:
(allow 1.5mm variation)
Joint completely fused into the parent material: (no overlap/cold lap)
1
Weld metal is free from surface porosity or inclusions:
1 pore = 1 defect 1 defect = 0.8 marks., 2 defects = 0.5 marks, 3 or more = 0
marks
Welded joint is free from undercut no greater than 0.5mm or equal to 10mm long =
1 defect (accumulative) 1 defect = 0.8 marks, 2 defects = 0.5 marks, 3 or more = 0
marks
1
2
1
1
1
1
1
1
1
1
1
1
1
1
Mark
awarded
Weld is free from excessive face concavity or convexity: (greater than 2mm from
the flat)
Fillet weld leg lengths are in accordance with specification:
1 defect = equal to10mm long (accumulative)
1 defect = 0.8 marks, 2 defects = 0.5 marks, 3 or more defects = 0 marks
Welded joint is complete: fully formed welds may not begin or terminate greater
than 3 mm from the ends of the plate
Joint 3 6mm thick low carbon steel 200mm long multi run with a leg length no less
than 10mm and no greater than 12mm
Surface slag, spatter and smoke residue has been removed from 95% of the joint
1
Welded joint is free from stray arc strikes: 1 strike = 1 defect 1 defect = 0.8 marks,
2 defects = 0.5 marks, 3 or more = 0 marks
Joint is set up with the vertical plate on the centre line of the horizontal plate: (allow
no more than 2mm variation)
Stop/starts are smooth on the capping run/s:
(allow 1.5mm variation)
Joint completely fused into the parent material: (no overlap/cold lap)
1
Weld metal is free from surface porosity or inclusions:
1 pore = 1 defect 1 defect = 0.8 marks., 2 defects = 0.5 marks, 3 or more = 0
marks
Welded joint is free from undercut no greater than 0.5mm or equal to 10mm long =
1 defect (accumulative) 1 defect = 0.8 marks, 2 defects = 0.5 marks, 3 or more = 0
marks
Weld is free from excessive face concavity or convexity: (greater than 2mm from
the flat)
Fillet weld leg lengths are in accordance with specification:
1 defect = equal to10mm long (accumulative)
1 defect = 0.8 marks, 2 defects = 0.5 marks, 3 or more defects = 0 marks
Welded joint is complete: fully formed welds may not begin or terminate greater
than 3 mm from the ends of the plate
Total
1
Feedback on performance, areas for improvement
Judge:
3
1
1
1
1
1
1
1
1
1
1
30