ARC WELDING BASICS

ARC WELDING BASICS

What is Arc Welding?
Why is Welding Important?

Why Learn to Weld?

ARC WELDING BASICS

What is Arc Welding?
Why is Welding Important?

Why Learn to Weld?

What is Arc Welding?

Arc welding is most commonly used to join two pieces of metal
The welder creates an electric arc that melts the base metals and filler metal (consumable) together so that they all fuse into one solid piece of metal

Steel Pipe Tack Welded

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Root Pass or Stringer Bead

Final weld after several beads are made

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 . its 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

Basic Steps of Arc Welding

Prepare the base materials: remove paint and rust Choose the right welding process Choose the right filler material Assess and comply with safety requirements Use proper welding techniques and be sure to protect the molten puddle from contaminants in the air Inspect the weld

Welding Safety
Welding can be safe when sufficient measures are taken to protect yourself and others from potential hazards Students should read and understand the following before welding:

Warning Labels Material Safety Data Sheets (MSDS) Students should also be familiar with the following information, Safety in Welding, Cutting, and Allied Processes

Warning Labels
Understand and follow all warning labels found: On welding equipment With all consumable packaging Within instruction manuals
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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

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 welding equipment

Do not make repairs yourself, alert your 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 fireproof pants Welding cap, helmet and safety glasses Ear protection ear plugs and muffs
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Remember!
Reading warnings Using proper protective clothing Equipment inspection Keeping your head out of the fume Proper ventilation
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Welder Responsibilities

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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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Basic Electricity and Welding

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The Arc Welding Circuit

The electricity flows from the power source, through the electrode and across the arc, through the base material to the work lead and back to the power source

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Basic Electricity
DC -

Voltage The electrical potential or pressure that causes current to flow Measured in Volts Current The movement of charged particles in a specific direction Measured in Amps Polarity DC- (Direct Current Electrode Negative) DC+ (Direct Current Electrode Positive) AC (Alternating Current)
AC

DC+

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METALS
Can All Metals Be Welded?

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Can All Metals Be Welded?

Most metals can be welded, but not all The three most common weldable metals include:
Mild Steel - inexpensive and strong Stainless Steel does not rust Aluminum does not rust and is light weight

Mild steel
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Stainless Steel

Aluminum

Gauge
Material thickness is sometimes measured by gauge from 36 (.004 in) to 3 (.2391 in)
For example, steel gauge and measurement in inches:

16 gauge = .051

14 gauge = .064

12 gauge = .081

10 gauge = .102

PLEASE NOTE: As the gauge number gets smaller the material thickness gets larger.

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TYPES OF JOINT
There are 5 types of joints

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Fillet and Groove Welds

Groove and fillet welds can be made on many types of joints

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Parts of a Weld

Heat Affected Zone Joint and Weld

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Fillet Weld Inspection

Fillet welds should: Have a flat to slightly convex face Be uniform in appearance Have equal leg size Have good wash-in into base materials
This is an example of a good fillet weld:

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Welding Symbols

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What are Welding Symbols?

Welding symbols give the welder specific instructions about the weld including: Placement Size Length Process Any other special notes
Welding symbols are
Universally used Governed by the AWS Found on engineering drawings

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Welding Symbols

Welding symbols contain information about the weld to be made

1. 2. 3. S leg dimension of the weld Triangle the weld is to be made on the arrow side of this joint Tail any additional information required (i.e. position the weld is to be made) Arrow - the joint the welding symbol applies to

4.

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Welding Positions
There are various positions that a weld can be made in:

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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 Take pride in workmanship
These welders work together to inspect a weld.

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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 Correctly fill out, maintain and submit time cards, work assignment cards, and other records as required Follow safe working practices

Agriculture teachers brush up on their welding skills at Lincoln Electrics Welding Educators Workshop
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