MEANING OF ARC WELDING

Arc welding is welding using the heat of an arc as a heat source. In arc
welding, positive voltage is applied to the electrode (welding rod/wire) and
negative voltage is applied to the base material. This makes an arc occur from
the base material to the electrode.
OR
Arc welding is a welding process that is used to join metal to metal by using
electricity to create enough heat to melt metal, and the melted metals, when
cool, result in a binding of the metals. It is a type of welding that uses a
welding power supply to create an electric arc between a metal stick
("electrode") and the base material to melt the metals at the point of contact.
Arc welding power supplies can deliver either direct (DC) or alternating (AC)
current to the work, while consumable or non-consumable electrodes are
used.

The welding area is usually protected by some type of shielding gas (e.g. an
inert gas), vapor, or slag. Arc welding processes may be manual,
semi-automatic, or fully automated. First developed in the late part of the
19th century, arc welding became commercially important in shipbuilding
during the Second World War. Today it remains an important process for the
fabrication of steel structures and vehicles.

In arc welding, positive voltage is applied to the electrode (welding rod/wire)

and negative voltage is applied to the base material. This makes an arc occur
from the base material to the electrode. The output current of the arc is about
5 to 1,000 A and the output voltage is about 8 to 40 V.
 ORIGIN OF ARC WELDING
Arc welding started in 1887 with the patent of a carbon electrode for arc
welding by Russians Nikolai Bernardos and Stanislaw Olszewski. The
process developed from there, with a metal electrode being patented in the
USA in 1890, and then coated electrodes in 1900. Equipment using
alternating current was introduced in 1911 but only became popular later.

USES OF ARC WELDING

The temperatures in arc welding get up as high as 6,500 degrees Fahrenheit.
Some of the most common uses for arc welding include;

● Steel erection
● Heavy equipment repair
● Pipeline welding
● Construction projects.

TYPES OF ARC WELDING

1. Shielded Metal Arc (SMAW) Welding: SMAW (sometimes called
"stick welding") is the most common and accessible type of arc
welding. It makes use of a consumable, hand-held electrode (the
"stick"). This electrode is coated with flux, which melts at the tip of the
electrode and produces the shielding gas, as well as a slag product that
protects the weld from oxidation during welding.

2. Flux Cored Arc Welding (FCAW): This is similar to SMAW welding,

but it is semi-automatic. The consumable electrode used contains flux
and it is continuously fed.
3. Metal Inert Gas (MIG) Welding: This welding technique uses
shielding gas to protect the molten metals from the atmosphere. The
metal consumable electrode is machine-fed.

4. Tungsten Inert Gas (TIG) Welding: This welding method uses a

non-consumable electrode made of tungsten, and therefore requires a
filler wire to be fed to make the weld. Shielding gas is necessary.

5. Submerged Arc Welding (SAW): This strategy is used with

automated welding processes, where the joint to be welded is
completely submerged in flux. The flux is conductive when molten,
and the weld is completed below this blanket of flux.

ARC WELDING EQUIPMENT

1. Welding Boots
2. Electrode
3. Chipping Hammer
4. Protective Equipment
5. Safety Glasses
6. Sheet metal gauge

ADVANTAGES OF ARC WELDING

Compared to many other welding methods, arc welding has many
benefits. Among the advantages of arc welding are:
1. Cost
2. Portability
3. Durability
4. Minimal Storage Space

1. COST: Arc welding gear is reasonably priced and cost-effective, and

since gas isn't used, the method frequently starts off needing less
equipment.

2. PORTABILITY: It is simple to bring the welding equipment for

operations outside because it is portable. Where there is electricity, its
power source can be utilized. Alternatively, generators can be used as a
backup if no electricity source is available.

3. DURABILITY: There is no need to clean the surface, and the process

of arc welding can be performed immediately on unclean metals.
Besides that, it also has a high impact strength and low corrosion
resistance. Any environment is suitable for the process of arc welding,
and the beads can be used to make designs on delicate metals.

4. MINIMAL STORAGE SPACE: The equipment needed for arc

welding is small and light; thus, there isn't much storage space
required. Businesses with little storage space will find this to be
beneficial because they can accommodate arc welding equipment
without any issues or challenges.

DISADVANTAGES OF ARC WELDING

Let's take a closer look at the disadvantages of arc welding and why
some welders may want to use another method for their projects
instead.
1. Lower efficiency
 2. Requires high skill level
3. It does not work well on thin metals
4. Requires a Power Source, Which May Not Be Available in All
Locations

1. LOWER EFFICIENCY: Arc welding typically produces more waste

than many other techniques, which can sometimes result in an increase
in project costs.

2. REQUIRES HIGH SKILL LEVEL: Arc welding project operators

require a high level of expertise and training, which not all specialists
have.

3. I T DOES NOT WORK WELL ON THIN METALS: Some thin

metals cannot be welded using arc welding.

4. REQUIRES A POWER SOURCE WHICH MAY NOT BE

AVAILABLE IN ALL LOCATIONS: Arc welding requires a power
source, since the electrical arc is fundamental to the welding process.
Some welding may need to be completed on sites where an electrical
source is not available. Electrical generators are a sound alternative and
can provide electrical power wherever it may be needed, but are not
always practical. Without a reliable power source, arc welding is
impossible.

SAFETY ISSUES RELATING TO ARC WELDING

Improper safety measures can make welding a risky and harmful activity.
Welding requires the use of an appropriate PPE (Personal Protective
Equipment) Kit. The primary health-related issues are as follows:
1. Inhaled substances
2. Potential harm to eyes
3. Heat, fire, and Explosion Hazards

1. INHALED SUBSTANCES: Welders are exposed to a variety of

potentially hazardous materials while welding. The smoke created, for
instance, during flux-cored welding contains a number of hazardous
oxides. Therefore, before beginning any welding procedure, we should
shield our faces.

2. POTENTIAL HARM TO EYES: The eyes can sustain significant

damage from the high-Intensity spark produced by this welding
procedure. When looking at the welding process directly, the eyes can
turn red and cause pain for days. As a result, welding goggles must be
worn to safeguard the eyes while welding.

3. HEAT, FIRE, AND EXPLOSION HAZARDS: Welding can generate

a lot of heat since the temperature rise in the core can reach up to 3593
degrees Celsius. The sparks can land on the body, or an explosion could
occur. As a result, we need to protect our bodies with appropriate gear
while welding. Additionally, we need to watch out for any explosive
materials that might be nearby the welding area.

THINGS TO CONSIDER IN ARC

WELDING/SAFETY PRECAUTIONS
1. VENTILATION: The welder should be located in an area with
adequate ventilation. In general, when welding is being done on metals
not considered hazardous, a ventilation system that will move a
minimum of 2000 cubic feet per minute (CFM) of air per welder is
 satisfactory. However, many materials are considered very hazardous
and should be welded only in adequately ventilated areas to prevent the
accumulation of toxic materials or to eliminate possible oxygen
deficiency not only to the operator but to others in the immediate
vicinity. Such ventilation should be supplied by an exhaust system
located as close to the work as possible

2. FIRE PREVENTION: The arc welder is capable of producing

temperatures in excess of 10,000 degrees F.,it is important that the
workplace be made fire safe. This can be accomplished by using metal
sheets or fire resistant curtains as fire barriers. The floor should be
concrete or another fire resistant material. Cracks in the floor should be
filled to prevent sparks and hot metal from entering. When work cannot
be moved to a fire safe area then the area should be made safe by
removing or protecting combustibles from ignition sources. In certain
welding situations it may be necessary to ask someone to watch for
fires that could go undetected until the welder has finished the job.

3. SAFE OPERATION OF THE WELDER: It is important that anyone

operating an arc welder be instructed on its safe use by a qualified
teacher or welder.
Because of their potentially explosive nature, we strongly recommend
that no welding, cutting, or hot work be attempted on used drums,
barrels, tanks, or other containers under any circumstances.
If possible, work to be welded should be placed on a firebrick surface
at a comfortable height. Welding should never be done directly on a
concrete floor. Heat from the arc can cause steam to build-up in the
floor which could cause an explosion. The welder cables should be
positioned so that sparks and molten metal will not fall on them. They
should also be kept free of grease and oil and located where they will
not be driven over.
 Electric welders can be killed by electric shock. If the welding
operation must be done on steel or other conductive material an
insulating mat must be used under the operator. If the welding area is
wet or damp or the operator is actively perspiring then he/she should
wear rubber gloves under the welding gloves.

4. FIRST AID: The welding area should always be equipped with a fire
blanket and a well stocked first aid kit. It is desirable that one person be
trained in first aid to treat the minor injuries that may occur. All
injuries, no matter how minor they may seem, can become more serious
if not properly treated by trained medical personnel.

KEY POINTS TO REMEMBER

● Be sure the welder is properly installed and grounded
● Never weld without adequate ventilation.
● Take proper precautions to prevent fires.
● Protect your entire body with fire retardant clothing, shoes, and gloves.
● Wear eye protection at all times.
● Weld only in a fire safe area.
● Never do any welding, cutting, or hot work on used drums, barrels,
tanks, or other containers.
● Mark metal "HOT" with a soapstone.
● Keep a well stocked first aid kit handy.