An integrated lesson

Introduction
What is Arc Welding?
Why is Welding Important?
Why Learn to Weld?

Basic Electricity and the Science of

Welding

Electricity
Energy Transfers
Changes of State
Chemical Reactions

Welding Safety
Careers in Welding

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Arc welding is a process used to join two

pieces of metal together.

How does it work?

A welder creates an electric arc that melts the

metal and filler rod to create a pool of molten

metal that hardens to fuse the two pieces of
metal together.

Why is welding important?

Many of the things you use need to be welded.

Your parents car

Power line towers
Your school desk
Your bicycle

dcist.com

www.cunninghamcycles.com

www.topspeed.com

assembly.state.ny.us

Why Learn to Weld?

Welding can help build a successful career to
earn money to buy the things you want.
Skilled Welders are in high demand.
Welding is challenging and high tech.

www.universalwelding.com
www.weldingschools.com

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Voltage The electrical potential or

pressure that causes current to flow

Current The movement of charged

particles in a specific direction

Measured in Volts

Measured in Amps

Polarity
DC- (Direct Current
Electrode Negative)
DC+ (Direct Current
Electrode Positive)
AC (Alternating Current)

DC -

AC

DC+

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

Circuit click on the link

to learn more.
Circuit Info.

Use the following links to learn how

electricity works in a circuit
Conductors, Insulators, and electron flow
Current and Voltage in a Circuit
Resistance
Ohms Law

The electron flow you just learned about

is what creates the arc in arc welding.
This is a form of electrical energy

How do we use that electrical energy to fuse

metals together?

The energy transfers that take place in welding

Electrical The arc created by the

electric current is
converted into heat
Thermal because of the
resistance of
electron
flow. The heat melts
the metal to fuse it
together.

Here are some places to look to learn

more about energy and energy transfers.
Forms of Energy
Energy Transformations

Changes of State and Chemical Reactions

During the welding process the metal changes

states or forms.
What are the states of matter?
Solid
Liquid
Gas
Plasma
Click here to learn more about the changes of state

Changes of State and Chemical Reactions

So what changes of state occur during welding?

Initially the metal is a solid
When the arc starts the solid is converted into a

liquid
Some of the liquid is converted into a gas vapor
When the arc stops the liquid cools to form a solid
again this is the newly formed weld joint
Solid Liquid Solid
(gas vapor)

Changes of State and Chemical Reactions

Chemical Reactions
During the welding process certain chemical

reactions take place.

Hydrogen, Oxygen, and Nitrogen can react in the
weld puddle and cause changes in the structure of
the weld weakening the weld.

pt.chemicalstore.com

Because of the chemical reactions, energy

transfers, and electricity involved in welding
proper safety must be addressed
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 (ANSI

Z49.1)
Lincoln Electrics Arc Welding Safety (E205)

http://www.lincolnelectric.com/knowledge/training/weldcurriculum.asp

Understand and follow all warning labels

found:
On welding equipment
With all consumable packaging
Within instruction manuals

www.jpbrandit.com
http://www.lincolnelectric.com/knowledge/training/weldcurriculum.asp

Material Safety Data

Sheets (MSDS) are:

Required by law and

OSHA
Created by the
manufacturer of a
product per OSHA
guidelines
Designed to inform
users
Shipped with every
box of consumable
product
Available free online
at:

www.lincolnelectric.com/produc
ts/msds/
http://www.lincolnelectric.com/knowledge/training/weldcurriculum.asp

MSDS outlines a
products:
Identity and

composition
Potential hazards
Safe use
Handling
information
Manufacturer
contact
information

http://www.lincolnelectric.com/knowledge/training/weldcurriculum.asp

Protect yourself
and others from
potential hazards
including:
Fumes and Gases
Electric Shock
Arc Rays
Fire and Explosion
Hazards
Noise
Hot objects

http://www.lincolnelectric.com/knowle
dge/training/weldcurriculum.asp

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

http://www.lincolnelectric.com/knowledge/training/weldcurriculum.asp

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

http://www.lincolnelectric.com/knowledge/training/weldcurriculum.asp

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

http://www.lincolnelectric.com/knowledge/training/weldcurriculum.asp

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

http://www.lincolnelectric.com/knowledge/training/weldcurriculum.asp

Education
Penn College of Te
chnology
Penn College
Welding Video
Welding Schools

Careers
American Welding
Society
Career Guide
Welding Jobs

pro.corbis.com
www.sun-tech.org

Here are some possible areas you can start a

career in welding

Racing
Engineering
Farm
Auto Technician
Sculpting
Maintenance
Iron worker
Robotics
Production welder
Fabricator
And many more

Do you want to learn more about welding

and how to weld? If so, go to the link
below for more information on how to
weld.
This is to be used if your school has
access
http://www.lincolnelectric.com/knowledge
/training/weldcubrriculum.asp

http://www.lincolnelectric.com/knowledge
/training/weldcurriculum.asp
http://www.weldinginfocenter.org/sci_tech
/index.html
http://www.pct.edu/degreesthatwork/weld
ing.htm
http://www.allaboutcircuits.com/vol_1/ind
ex.html
All photographs are cited next to
photograph