Arc Welder I. Competencies Given a functional welder, instruction and demonstration of use, each student will be able to: A.

Identify the major parts of the arc welder. B. Pass a written test of safety and operating procedures of the arc welder with a minimum of 100 percent accuracy. C. Demonstrate, to the satisfaction of the instructor, ability to safely use an arc welder while performing assigned tasks. II. Instructional Materials and Procedures A. Identification of Basic Arc Welder Parts 1. 2. 3. 4. 5. 6. Switch Power cord Ground cable terminal Amperage output indicator Ground clamp Polarity switch 7. Amperage adjustment handwheel 8. Helmet 9. Electrode holder 10. Electrode cable terminal


10. Place electrode stubs in a suitable container. Never breath fumes when welding lead. and water. zinc. 76 . Guard against the use of damp or wet clothing when welding. The use of such clothing increases the possibility of electrical shock. Keep the welding curtain in place at all times. oil. bronze. 9. and grease. 12. volatile. Never weld while standing in water or on damp ground. Completely submerge metal in water when cooling. (Ex. hot metal. grease. brass. chromium. Place it on an insulated hanger. Wool or cotton clothing. manganese. Do not carry matches. 3. sharp edges. butane or propane lighters or other flammables in you pockets while welding. 2. Make sure the work area is free of flammable. 7. Some synthetic fibers are highly flammable. open flames. DO NOT wear clothing made of synthetic fibers when welding. welding apron or leathers. and leggings are recommended. Keep the welding area clean and free of tools. or explosive materials. These fumes are toxic and may cause sickness or death. Always wear protective clothing suitable for welding. Arc Welder Safety 1. Protect welding cables from sparks. steel. or galvanized steel.B. 6. cadmium. this prevents steam from burning you. 8. Always wear industrial quality eye protection when welding and cleaning welds. beryllium. and coal dust). A good exhaust system is essential when welding within a confined laboratory. high top leather shoes. An electrode holder should never touch a compressed gas cylinder. Shield others from the light rays produced by arc welding. gasoline. scrap metal. 4. gauntlet gloves. 5. Use tongs or pliers to handle hot metal after it has been welded. 11. Do not allow stubs to get on the floor in the welding area. propane. Never lay the electrode holder on the welding table or a grounded metal surface. A number 10 filter lens is minimum for most arc welding processes. 13.

keep hands and clothing dry at all times. Turn the welder off and store cables before leaving the welding area. Disconnect the power to a welding machine before making any repairs. 77 . Make adjustments in polarity and amperage only when the machine is not under load. Use a dry chemical type “C” extinguisher to put out an electrical fire. treat any cuts or burns promptly. Treat all cuts or burns promptly. 3. Use a fire blanket to smother clothing fires. Do not use cables with frayed. Never weld with the cables coiled over the shoulders. Turn on the fumes removal system before starting to weld. 17. 2. Check to make sure the welding machine is properly grounded. Keep welding screens in place to protect on-lookers from arc flash. Arc Welder Operating Procedures 1. Dampness on the body increases the chance of electrical shock when welding. Wear a welding helmet with a correct shade filter lens. 18. 8. Switching the current while the machine is under load will cause an arc to form between the contact surfaces. C. Inspect electrode holders for defective jaws and poor insulation. 16. 7. A number 10 to 12 filter lens is usually satisfactory for general purpose welding. Do not weld in damp areas. The welding equipment should be installed according to provision of the National Electric Code and the manufacturers recommendations. 10. Most welding helmets provide a flip-up device to allow chipping or grinding to be done without removing the helmet. The operator should keep all cable connections tight. 9. 19. 4. 15. cracked or bare spots in the insulation. A power disconnect switch should be conveniently located near each welding machine.14. Cool and store any hot metal before leaving the work area. 5. Report accidents to the instructor immediately. 6.

close the valve and mark cylinders “empty”. 17. check for water leakage often. Be sure that all gas cylinders are chained in an upright position before starting to weld. If an electrode sticks. 78 . Avoid welding directly on concrete floors. Residual moisture in the concrete may be turned to steam resulting in the concrete exploding. 12. When using water cooled equipment. If twisting fails to free the electrode.11. Use an audible signal such as “cover” to indicate to others that you plan to strike an arc. 15. When gas cylinders are empty. 18. Keep the cylinder caps in place when the cylinders are not in use. release the electrode from the electrode holder. 14. 16. 19. Turn off the switch on the welder and use pliers to break the electrode free. try to twist it free. Handle all compressed gas cylinders used in Mig and Tig welding with extreme care. 13. Clear all combustible materials from the welding area before welding. Do not weld in areas that store compressed gas cylinders.

cracked. wool clothing cotton gloves a heavy coat tinted glasses 2. 1. a. spliced 79 . b. noise light rays heat gas 5. The welding area should be kept free of _________. a. c. fuels and solvents ultraviolet rays infrared rays electrodes 4. d. d. c. b. grease. c. cut or frayed d. c. soldered c. a. Arc welding produces harmful _________. a. When arc welding one should wear ________. d. Written Test Arc-Welding Safety and Operation Test Name______________________ Date_______________ Class____________________ Multiple Choice – Place the letter of the most correct answer on the answer sheet. For proper eye protection when arc welding the minimum shade number of the filter lens should be __________. welded b. a. b. When arc welding do not use cables that are _________. d.III. 4 6 10 12 3. b.

Careful handling of compressed gas cylinders includes _________. d. Saturation of clothing by moisture or perspiration increases the risk of _________. b. paper in his/her pockets cigarette lighters rags tools 9. gauntlet gloves cotton gloves synthetic material gloves work gloves 8. the operator should ________. a. d. keeping caps in place fastening in an upright position labeling when empty all of these a and b above 7. When welding the operator should never lay or stand _________. b. e. c. Gloves used for arc welding should be __________. the operator should not carry _________. d. When welding.6. When starting to arc weld. d. b. b. turn on the exhaust fan clean area of scraps and tools shield others from arc rays all of these 80 . c. a. b. a. weld burns electrical shock getting a flash welder fatigue 11. d. on concrete floors on damp ground on metal on wood structures 10. c. a. c. b. c. d. a. c. a.

Welding cables should be protected from __________. the first thing one should do is _________. c. If a fellow student’s clothes catches on fire. gloves aprons tongs or pliers rags 16. c. b. Any cuts or burns should be _________. d. in a container on the floor on the welding table in the cooling barrel 15. d. throw water on the person use a fire extinguisher wrap the person with a fire blanket call the school nurse 81 . treated at the end of class treated promptly by an authorized person coated with salve packed in ice 17. sparks and flames excessive voltage excessive amperage all of these 13. b. a. c. a. d. running a bead not under load warmed up turned off 14. d. a. d. c. c. a. b. Electrode stubs should be placed __________.12. b. b. c. The amperage setting should be made while the welding machine is ________. d. Hot metal should be handled with _________. a. b. a.

c. d. b. When working in an area with other people. what should be done before an arc is struck? a. b. damage smoke poisonous gas fumes explosion of the concrete 19. d. a. If the electrode holder is placed on a grounded welding table with the welding machine on. b. c. d.18. what will happen? a. Check the electrode holder Tell others you plan to strike an arc Check the cables for cuts and burned insulation All of these 20. Welding directly on a concrete floor may cause ___________. c. Nothing The welding machine will automatically shut off A deadly electrical circuit is established An arc will be struck 82 .

The fumes removal system is operating while welding is being performed. open flames. A special container is used for depositing spent electrode stubs. 11. Performance Test for the Arc-Welder The student performs the following while operating the arc welder. The electrode holder is placed in an insulated hanger when it is not in use. The operator wears approved eye protection while welding and grinding welds.Student_______________________________ IV. 3. ____________________ _______ Signed (Student) Date _____________________ _______ Signed (Teacher) Date 83 . 7. Compressed gas cylinders are securely fastened in an upright position. Work procedures used are safe and acceptable. Cables are protected from sparks. Yes No N/A 1. The operator keeps all cable connections tight and insulated while welding. The operator signals others when he or she is about to strike an arc. hot metal. The work area is kept clean and free of hot metal. 6. Tongs or pliers are used for handling hot metal. 5. Correct work procedures are used when arc welding. 13. 8. 4. Suitable protective clothing is worn by the operator when welding. ___ ___ ___ ___ ___ ___ ___ ___ ___ ___ ___ ___ ___ ___ ___ ___ ___ ___ ___ ___ ___ ___ ___ ___ ___ ___ ___ ___ ___ ___ ___ ___ ___ ___ ___ ___ ___ ___ ___ ___ ___ ___ Comments_________________________________________________________ __________________________________________________________________ __________________________________________________________________ I hereby certify that the student had satisfactorily demonstrated ability to operate the arc welder by passing the above performance test. and grease. 2. 12. Flammable materials are kept out of the welding areas. oil. 14. 9. scrap and tools. 10.

___ A. Amperage adjustment handwheel 84 . Power cord ___ D. Switch ___ G. Polarity switch ___ B.Arc Welder Parts Identification Test Name_______________________ Match the number of each arc welder part with the correct part name. Amperage output scale ___ J. Ground cable terminal ___ H. Electrode cable terminal ___ F. Electrode holder ___ I. Helmet ___ E. Ground clamp ___ C.

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