WELDING

Processes
Why is Welding Important?
• Many things around us are welded …
– Pipelines that bring fresh water
– Towers that carry electricity to houses
– Cars and buses that take people where they need to go
Why Learn to Weld?
• Welding is so HOT …. it’s COOL!
• Welding can help build a successful career so you can get the things you want
in life
• Skilled welders are in demand – people use things that are welded everyday!
• Welding can be fun and safe
• It is challenging and high-tech
Careers in Welding
Job opportunities in welding are changing • Robotics
… • Ironworker/ Skilled Trades
Welding can be valuable as a job skill or as a
full-time job • Auto Technician
Engineering • Artist
• Racing • Metal Sculpting
• Industrial Sales • Shipbuilding
• Farm Repair and Fabrication • Construction
• Production Welding • Owning Your Own Business
• Military
• Teaching
• Maintenance
Arc Welding Safety
• Protect yourself and
others from potential
hazards including:
– Fumes and Gases
– Electric Shock
– Arc Rays
– Fire and Explosion
Hazards
– Noise
– Hot objects

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Fumes and Gases
• Fumes and gases can be
hazardous to your health
• Keep your head out of the
fumes
• Use enough ventilation,
exhaust at the arc, or both,
to keep fumes and gases
from your breathing zone
and the general area
• See product labeling and
MSDS for ventilation and
respirator requirements

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Electric Shock
• Electric shock can kill
• Do not touch live electrical
parts
– Primary Voltage –230, 460
volt input power
– Secondary Voltage – 6 to
100 volts for welding
• Insulate yourself from
work and ground
• Follow all warnings on Do not make repairs
yourself, alert your
welding equipment instructor immediately!

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Arc Rays
• Arc rays can injure eyes and
burn skin
• The welding arc is brighter
than the sun
• Precaution must be taken to
protect your eyes and skin
from UV radiation
• Wear correct eye and body
protection

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Fire and Explosion Hazards
• Welding sparks can cause
fires and explosions
• Sparks and spatter from the
welding arc can spray up to
35 feet from your work
• Flammable materials should
be removed from the welding
area or shielded from sparks
and spatter
• Have a fire extinguisher ready
• Inspect area for fires 30
minutes after welding

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Noise
• Loud noises can damage your hearing
• Keep loud noises at a safe level by using proper
hearing protection such as:
– Ear plugs
– Ear muffs

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Protective Clothing
Welders must wear protective
clothing for
– Protection from sparks, spatter and UV
radiation
– Insulation from electric shock

• Protective clothing includes …

– Fire-proof clothing without rolled sleeves,
cuffs or frays
– Work boots
– Welding gloves, jackets, bibs, and fire-
proof pants
– Welding cap, helmet and safety glasses
– Ear protection – ear plugs and muffs

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Welding Processes and their
Applications
• Oxyfuel Gas Welding (OFW) – a
group of welding process that
produces coalescence by heating
materials with an oxyfuel gas
flame or flames, with or without
pressure, and with or without
the use of filler material.
• Shielded Metal Arc Welding
(SMAW) – an arc welding
process that produces
coalescence of materials by
heating them with an arc
between a covered electrode
and a workpiece; shielding is
obtained from decomposition of
the electrode cover pressure is
not used, and filler metal is
obtained from the electrode.
SMAW Principles
• The American Welding Society
defines SMAW as Shielded Metal
Arc Welding
• SMAW:
– Is commonly known as ‘Stick’
welding or manual arc welding
– Is the most widely used arc welding
process in the world
– Can be used to weld most common
metals and alloys
Advantages of SMAW
• Low initial cost
• Portable
• Easy to use outdoors
• All position
capabilities
• Easy to change
between many base
materials
What safety precautions should
be taken by these welders?

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Limitation of SMAW
• Lower consumable
efficiency
• Difficult to weld very
thin materials
• Frequent restarts
• Lower operating factor
• Higher operator skill
required for SMAW
than some other
processes Building a barge in a large shipyard

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• Gas Tungsten Arc Welding
(GTAW) – an arc welding process
that produces coalescence of
materials by heating them with
an arc between a
nonconsumable tungsten
electrode and a workpiece,
shielding is obtained from a gas,
and filler metal may or may not
be used.
• Gas Metal Arc Welding
(GMAW)– an arc welding
process that produces
coalescence of metals by heating
them with an arc between a
continuous filler metal electrode
and a workpiece, shielding is
obtained entirely from an
externally supplied gas.
• Flux Cored Arc Welding (FCAW) –
an arc welding process that
produces coalescence of metals
by heating them with an arc
between a continuous filler metal
electrode and a workpiece,
shielding is provided by a flux
contained within the tubular
electrode, and additional
shielding may or may not be
obtained from an externally
supplied gas or gas mixture.
• Submerged Arc Welding (SAW) – an
arc welding process that produces
coalescence of metals by heating
them with an arc or arcs between a
bare metal electrode or electrodes
and a workpiece; the arc and
molten metal are shielded by a
blanket of granular, fusible material
on the workpiece; pressure is not
used, and filler metal is obtained
from the electrode or sometimes
from a supplemental source.
• Plasma Arc Welding (PAW) - an arc welding
process that produces coalescence of
metals by heating them with a constricted
arc between a nonconsumable electrode
and a workpiece (transferred arc), or the
electrode and a constricting nozzle
(nontransferred arc).
• In PAW, shielding is obtained from the hot,
ionized gas issuing from the torch, and this
maybe supplemented with an auxiliary
source of shielding gas, shielding gas maybe
an inert gas or a mixture of gasses, and
filler metal may or may not be used.
What are the
Responsibilities of a Welder?
• Welders have many areas of
important responsibilities
• These relate to:
– Arc Welding Safety
– Knowledge – Content
– Attitude – Reactions
– Skills – Performance
– Work Habits – Daily Functions

Always keep safety in

mind when welding

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Knowledge - Content

• Welding can teach

you about….
– Science when applying
metallurgy, chemistry,
electricity, etc.
– Math when calculating
angles, joint design, and
weld size
– English when
communicating and
interpreting drawings,
codes, and procedures
– Technical areas when
performing the actual How much science and
welding applications math went into the
development of this bike?

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Attitude
• The best welders
demonstrate a can-do
attitude when performing
welding processes
• This means being able to…
– Work as a team member
– Communicate ideas to others
– Listen to opinions of others
– Promote a positive attitude
– Provide solutions to problems These welders work together
to inspect a weld.
– Take pride in workmanship

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Skills/Performance
• A welder must
demonstrate technical
skills when performing
welding processes
• A welder must know how
to:
– Use hand tools and materials,
to operate equipment in a safe,
accurate, and consistent
manner
– Acquire and evaluate
information needed for
problem solving
– Complete quality work
– Maintain equipment
There is no room for poor
workmanship in NASCAR

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Work Habits/Daily Functions
• A welder must practice good
working habits when
performing welding
processes
• This means being able to …
– Follow detailed verbal and
written instructions
– Maintain workspace,
equipment, and tool
cleanliness Agriculture teachers brush
– Correctly fill out, maintain and up on their welding skills at
submit time cards, work Lincoln Electric’s Welding
assignment cards, and other Educator’s Workshop
records as required
– Follow safe working practices

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Welding Certification
• What is a welding certification?
– Welding certifications are used to test a welder’s knowledge and
welding skill
– Certifications are available for many different processes, materials, and
positions.
• Who certifies welders?
– Certification programs are offered by many different types of
organizations:
 Companies
 Skilled Trades
 Military
 Ship Builders
 Pipelines
 The American Welding Society

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