Craftsman Shielded Metal Arc Welding study plan

Set up and shut down an SMAW station by completing a 10-point pre-start checklist that covers leads, ground clamp, electrode holder insulation, ventilation, and fire watch.

Select and don the correct PPE for a given task, then justify each item (helmet shade, FR sleeves, leathers, respirator) in a written log.

Strike and re-strike an arc 20 times without sticking, then run five straight stringer beads on 6 mm carbon steel in the flat position.

Diagnose arc blow from bead appearance and apply two corrective measures (ground repositioning, shorter arc, AC switch).

Run stringer and weave beads in the horizontal (2F) and vertical-up (3F) positions while keeping bead width within 2.5 times the electrode diameter.

Adjust amperage and arc length for E6010, E6013, and E7018 electrodes and record how each behaves at low, optimal, and high current.

Apply fume-control and hot-work-permit requirements: position a portable extractor, verify fire watch timing, and inspect the area for combustibles before and after welding.

Demonstrate emergency shutdown and response steps for an electrical contact and a clothing fire scenario.

Identify and classify at least eight weld discontinuities (porosity, slag inclusion, undercut, overlap, lack of fusion, crater crack, spatter, arc strike) from your own practice coupons.

Perform a guided-bend test on a coupon and interpret the result against acceptance criteria for cracking and fusion.

Match constant-current versus constant-voltage power sources to SMAW and explain why CC is used, including the effect of arc-length change on amperage.

Calculate allowable welding current from a duty-cycle rating (for example, 60% at 200 A) and convert it to a 100% duty-cycle value.

Identify ten numbered metal samples by spark test, magnet test, and code/numbering reference (carbon steel, stainless, cast iron, aluminum).

Explain how carbon equivalent and cooling rate affect hardenability and preheat decisions for a given steel.

Select polarity (DCEP, DCEN, AC) for a specified electrode and verify the setting on the machine before welding.

Prepare plate surfaces by removing mill scale, rust, oil, and moisture, and record the cleaning method used on each coupon.

Prepare butt, lap, T, and corner joints to drawing dimensions, then set root gap, land, and alignment within ±1 mm of the specified values.

Tack-weld an assembly in the correct sequence to control distortion, and check square, flatness, and root opening before welding.

Decode AWS A5.1 electrode designations (for example, E7018-1 H4R) into strength, position, coating, current, and diffusible-hydrogen requirements.

Store, redry, and handle low-hydrogen electrodes according to manufacturer limits, and document oven temperature and holding time.

Weld a 3G (vertical-up) and 4G (overhead) coupon with a root pass, fill, and cap that pass a visual inspection for leg size, undercut, and overlap.

Control interpass temperature and heat input by measuring with a thermometer and adjusting travel speed and amperage.

Compare destructive and non-destructive test methods (bend, break, visual, penetrant, ultrasonic) and state what each can and cannot reveal.

Trace three defects from your coupons to a root cause in current, travel angle, arc length, or joint cleaning, and rewrite the technique step that fixes each.

Interpret welding symbols on a provided drawing, including arrow side versus other side, groove and fillet types, size, length, pitch, and tail references.

Apply code requirements for preheat, fit-up tolerance, inspection extent, and acceptance criteria from a structural welding code to a sample joint.

Convert drawing callouts into a step-by-step weld sequence with parameters, then check the finished joint against the symbol.

Explain how the applicable code or standard governs inspection frequency and qualification records.

Complete a timed 100-question mock exam across all eight domains and review every missed item to a verified source.

Re-weld the weakest position or joint from Weeks 1–7 and self-inspect it against the same acceptance criteria.

Audit your personal safety and equipment checklist against the exam safety domain and correct any gaps.

Finalize a logbook of coupons, parameters, defects, and fixes that documents your progression.