This 4-day course is designed to take a welder from basic arc striking to mastering the "Fillet" weld in every orientation. A Fillet Weld (F) is used to join two pieces of metal at an angle (usually 90°), such as T-joints, Lap joints, and Corner joints.

By the end of this course, you will be able to manage the molten "puddle" against the force of gravity, which tries to pull the metal out of the joint as you move from flat to overhead positions.

Day 1: Foundations & 1F (Flat Position)

The focus today is on "The Arc" and the easiest position. In 1F, gravity is your friend, helping the molten metal settle deeply into the root of the joint.

• Machine Setup: Learning the difference between AC and DC current and how to set the correct amperage for different electrode diameters.

• The "CLAMS" Technique: Focusing on Current, Length of Arc, Angle, Manipulation, and Speed.

• 1F Techniques: Welding a T-joint where the joint is tilted so the weld is performed in a "V" shape.

• Weld Profile: Learning to identify a "good" weld vs. one with slag inclusions or porosity.

Day 2: 2F (Horizontal Position)

Today, gravity becomes a factor. In the 2F position, the molten metal wants to "sag" onto the bottom plate, potentially causing a defect called "overlap" on the bottom and "undercut" on the top.

• Work Angle: Adjusting the rod angle slightly upward (usually 45° to 50°) to push the molten metal back up against the vertical plate.

• Travel Speed: Increasing speed slightly to prevent the puddle from becoming too large and uncontrollable.

• Multi-pass Welds: Learning how to stack beads to create a larger, stronger joint without losing the profile.

Day 3: 3F (Vertical Position - Up & Down)

This is often considered the "make or break" day for many students. Vertical welding requires a specific manipulation of the rod to keep the metal from "dripping" down.

• Vertical-Up (3F Up): Using the "Z-weave" or "Triangle" motion. You dwell on the sides of the joint to ensure fusion and move quickly through the center to prevent the puddle from falling.

• Vertical-Down (3F Down): Used primarily for thin sheets. It is fast and provides less penetration but results in a very clean finish.

• Amperage Adjustment: Usually, you will drop your amperage by 10–15% compared to flat welding to make the puddle "freeze" faster.

Day 4: 4F (Overhead Position)

The most intimidating position for beginners. The challenge is psychological as much as it is physical—keeping the molten metal in the joint while sparks fall toward you.

• Arc Length: Keeping an extremely "tight" arc (short distance). A long arc in the 4F position will cause the metal to rain down on your gloves.

• Body Positioning: Learning how to brace your arms and shoulders so you can move smoothly across the joint without shaking.

• Safety Mastery: Ensuring your leathers, hood, and neck protection are perfect.

• Final Practical Test: Performing a "Mock Test" on all four positions (1F–4F) to verify your competency.