TECHNOLOGICAL UNIVERSITY OF THE PHILIPPINES

Ayala Blvd., Ermita Manila, 1000, Philippines

COLLEGE OF INDUSTRIAL EDUCATION

CRISTOBAL, ROWELA D. DR. EMELITA NUYDA

BTVTED-COMPROG 3B SEMINAR IN TLE

RESEARCH WORK 9

WELDING and REF. & AIRCON

10 DIFFERENT WELDING TOOLS AND EQUIPMENT

AUTO-DARKENING WELDING HELMET

Auto darkening welding helmets safeguard a

welder from flying sparks and debris hitting the
face and also protects their eyes from the
blindingly fluorescent welding spark.

ELECTRODE HOLDER

An electrode holder, commonly called a stinger, is

a clamping device for holding the electrode
securely in any position. The welding cable
attaches to the holder through the hollow insulated
handle.

CHIPPING HAMMER

A Chipping hammer is used for removing welding

slag and welding spatter from welds.

WIRE BRUSH
A wire brush is used for cleaning off debris
before, after and between each pass to avoid
contamination of the weld.

WELDING CLAMPS
Clamps are versatile tools that serve to
temporarily hold work securely in place. They are
used for many applications including carpentry,
woodworking, furniture making, welding,
construction and metal working.

TIG WELDING GLOVES

TIG welding gloves have thinner and more
flexible material with fire-resistant fabric.

WELDING JACKET
welding jackets are thick and fire resistant, and
they protect a welder’s body well.

.
MIG WELDER
MIG welding, also known as Gas Metal Arc
Welding (GMAW), is a process that utilizes a
continuously fed solid electrode, shielding gas
from an externally supplied source, and electrical
power to melt the electrode and deposit this
molten material in the weld joint.
 WELDING MARKER
marker is used to mark the metal and determine
where the welds are to be made.

MIG PLIERS
MIG pliers are essential components of a welder’s
kit. They can be used for various small functions.

Safety measures to follow when doing welding process

Why Welding Safety Is So Important

As welding presents many potential hazards, it’s crucial for welders to practice safety by taking the
following steps:

 Analyzing surroundings
 Using tools and equipment in the way they are intended
 Following all manufacturer guidelines
 Ensuring others are not in harm’s way while working
Accidents happen, but many injuries can be avoided by having an understanding of what to do and what
not to do when working in a welding environment. Before starting any project, welders must take the time
to ensure they know how to execute the task safely above all else. It’s the most important thing they can
do to protect themselves and those around them.

11 Welding Safety Rules to Follow

So how does one avoid these hazards? Here are 11 tips for practicing safe welding:

1. Study and Study Some More

 The most successful welders know safety procedures like the back of their hand. They take the
time to educate themselves on safety guidelines set in place by both national organizations and
the company they work for, which helps to ensure a safe, productive workspace for all.

 It’s also important for welders to review manufacturer instructions before operating equipment.
Welders should never assume they know how to use a piece of equipment before they’ve read and
understood the manufacturer’s guidelines for safe operation.

2. Protect Yourself from Fumes and Gases

 Exposure to fumes and gases can be controlled by providing adequate ventilation in the work
area. Some employers will provide a fan, an exhaust system or exhaust hoods to remove fumes
and gases from the area welders are working in.

 When necessary, welders should wear a respirator to protect themselves from breathing in
harmful substances. If you ever feel as though your breathing is inhibited, express your concerns
to a supervisor immediately.

3. Take Precautions Against Electrocution

 Electric shock is one of the most important topics for welders to be educated in, as it can pose an
immediate and serious risk.

 To avoid electrocution, welders must always inspect the electrode holder for damage before
starting their weld. They also must ensure their gloves are dry and in good condition, never touch
the metal parts of the electrode holder with skin or wet clothing, and keep dry insulation between
their body and the ground or metal being welded.

4. Check Your Equipment

 A good welder always checks to ensure their equipment is functioning properly and is fully
grounded before using it. Even the most experienced welders should regularly check their
equipment for common wear and tear, such as a frayed wires or leaking hoses, as this can
increase the chances of an accident occurring. 

5. Avoid Clutter

 A cluttered workspace is one of the most common causes of welding fires and explosions. Sparks
from the welding arc can fly up to 35 feet in distance, so it’s important to keep your workspace
clear, especially of any flammable materials.

 As a general rule, always stay organized and keep everything in its place. Your workspace should
only contain the tools and equipment you’re using for that specific project.

6. Know Your Environment

  Before starting a weld, take inventory of your environment. Knowing where tools and equipment
are located not only increases your efficiency, but it’s vital for your safety. For example, it’s
important to know the location of fire alarms, emergency exits, fire extinguishers, sand buckets or
other equipment you would need to put out flames in the event of a fire.

7. Dress for the Job

 Wearing the proper attire is critical for welders. Any exposed skin is vulnerable to the harmful
effects of infrared and ultraviolet rays, so welders must always ensure they are fully covered.
Additionally, pant cuffs, pockets or any loose items of clothing can catch flying sparks, so it’s
important to keep them secured.

8. Wear the Right PPE

Selecting the proper PPE for the job is one of the most important decisions you can make to protect
yourself as a welder. Here’s a quick look at the types of PPE welders should wear:

 Ear protection: If readings of noise average above 85 dB for eight continuous hours, you are
required to use hearing protection at all times.
 Eye and face protection: This includes safety glasses, face shields and depending on the project,
helmets.
 Heat and radiation protection: In order to protect themselves from heat and radiation, welders
must wear flame-resistant outerwear, gloves to protect hands and lower parts of the arms, and
welding hoods and goggles.
 Fume protection: Fume extraction systems and respirators can help to protect welders from
exposure to harmful fumes.
 Electrical shock protection: In addition to taking the safety precautions outlined in tip #3,
welders must wear insulated clothing to protect themselves from electrocution.
 Foot protection: Leather shoes that are spark and heat resistant with coverage above the ankle
are best for foot protection. Pant legs should go over the shoes.

Avoid Stress Injuries

 Welding is a hands-on career that can lead to injuries without following the right precautions. In
order to protect yourself, always practice safe lifting techniques and be sure to break up your day
to stretch and allow your body to rest. This can help to avoid repetitive stress injuries, which
some welders are prone to.

Enforce Safety Procedures

 As a welder, it’s important to hold yourself and those around you accountable when it comes to
following safety guidelines. If you see a safety violation, report it’s in the best interest for you
and those you share a workspace with! Additionally, if you ever feel unsafe in your work area,
don’t be afraid to speak up.

Keep Learning
  The welding industry is constantly changing and evolving due to technology. As manufacturers
release new equipment and new techniques are adopted, it’s important to continuously educate
yourself on best practices—for both your skill and safety!

SMAW, GMAW AND TIG/MIG

In the world of welding there are three techniques which receive the majority of the attention. These are
SMAW (shielded metal arc welding), GMAW (gas metal arc welding), and TIG (tungsten inert gas)
welding. There are important differences in the process and capabilities of each, so it is important to
understand their unique characteristics.

SMAW

 SMAW stands for shielded metal arc welding. This is also commonly called ‘stick’ welding. In
SMAW, the electrode is a metal rod or stick held in the torch with a small clamp. The rod has a
solid coating of inert materials which vaporizes as you weld. This creates an inert cloud or gases
which protect the molten metal and displace any oxygen that might come into contact with it. The
gas cloud settles on the pool of molten metal as it cools, and is referred to as ‘slag’. The
disadvantage to SMAW is that the slag must be chipped off of the weld after it cools, and can
sometimes infiltrate the weld causing weakness.
GMAW

 GMAW stands for gas metal arc welding. This is also commonly referred to as metal inert gas
welding, or MIG welding. In GMAW the electrode is a roll of wire which the welder feeds out of
a ‘gun’ to the work piece. You control the speed of the wire, so you can make long welds without
stopping to replace a rod. This type of welding is generally considered to be the easiest to learn.
The gun also feeds out an inert gas such as Argon or CO2 to displace oxygen at the weld site.
This means you don’t have any slag to chip away, but you do need a tank and regulator to go with
a MIG welder.
TIG

 TIG stands for tungsten inert gas welding. Like GMAW, TIG welding uses a tank and inert gas to
shield the weld. In both GMAW and SMAW the electrode is consumed by heat and becomes part
of the weld. TIG stands out in that the tungsten electrode carries the arc, but is not consumed.
Tungsten withstands the heat of welding. TIG takes the most skill, since you have to hold a filler
rod in one hand and the gun in the other in order to accomplish this type of welding. It is usually
reserved for specialized types of welds.

Materials/consumables and equipment used in the different kinds of welding

Welding is the process of joining metals and thermoplastics by means of coalescence. It is an economical
and effective process for creating strong joints between two or more parts. Filler metals melt during
welding to create a strong joint. Flux is commonly used to produce a shield of gas around the weld pool
to prevent oxidation of the hot metals. Flux typically acts as a deoxidizer preventing the formation of
porosity in the weld pool. Flux and filler metals together are known as welding consumables.

Stick electrode, flux-cored wires, solid wires, SAW wires and fluxes are some of the welding
consumables employed during the welding process. However, flux does not form part of the final weld
and so is 'wasted' during the course of welding.

The welding industry's growth is highly dependent on the global steel consumption.

Welding finds application in a number of industries such as; building and construction, automobile and
transportation, marine, power generation, and oil and gas. The global welding consumables market is
forecast to witness high growth due to the positive outlook of end-use industries such as the automotive
and transportation, marine, and construction industries. However, the slow adoption of advanced
technologies, particularly in the developing countries poses a threat to this growth.

Welding consumables are segmented into:

 Arc welding.
 Resistance welding.
 Oxyfuel welding.
 Ultrasonic welding.
 Others (laser beam welding, etc.).
Welding consumables types include:

 Stick electrodes.
 Solid wires.
 Flux-cored wires.
 SAW wires.
 Fluxes.
 Others (including gases, etc.).

There are four main types of welding positions

Flat position

 Also referred to as a “down-hand” position, the flat position weld is the easiest and often the first
weld that new students learn. The metals to be joined are placed flat, and the welder passes the
electric arc over them, moving across the workpiece in a horizontal direction. The joint’s top side
is welded together allowing the molten material to move downward into its edges or groove
Horizontal Position
  The horizontal position is considered an out-of-position weld. Along with the vertical and
overhead, the horizontal position can be more challenging to perform and require a higher level of
skill.
 The weld axis is horizontal. How the position is executed depends on the type of weld. For a fillet
weld, the weld bead is placed where a vertical and a horizontal piece of metal meet at a 90-degree
angle. When performing a groove weld, the weld face will be along a vertical plane.
Vertical Position

 For a vertical position weld, both the weld and plate will lie vertically. One of the major problems
when performing this weld is the molten metal flowing downward and piling up. Welding in a
downhill or upward vertical position can prevent this issue.

Overhead

 The overhead position weld is the most difficult position to work in. The welding will be
performed with the two pieces of metal above the welder, and the welder will have to angle him
or herself and the equipment to reach the joints.
 One major issue can be the metal sagging from the plate. When the metal sags, it creates a crown.
To avoid this issue, the puddle of molten metal should be kept small.
Parts of a refrigerator

Internal Parts of a Refrigerator and Its Functions

Compressor
 A compressor is the main part of a refrigerator. It is the heart of the refrigerator and does the
job of cooling. The compressor consumes most of the electricity. It’s located at the back of the
refrigerator and is run by an electric motor. Without this part, your refrigerator is nothing but a
wardrobe.

Refrigerant
 Refrigerant is a cooling liquid that spreads inside the refrigerator and carries out the cooling
part. The compressor runs this refrigerant with the help of an electric motor. The refrigerant
keeps on recirculating through all the internal parts of the refrigerator on the loop.

Condenser
 The condenser is a copper tubing located at the back of the fridge. The heat produced in the
refrigerant needs to be absorbed by something. That is what the condenser does. There are fans
placed above the condenser unit to draw air over the condenser coils.

Evaporator
 The evaporator is a heat exchanger made of aluminum or copper tubing. The only purpose of
the evaporator is to absorb the unwanted heat from the food. The refrigerants absorb the heat
from the food to be cooled in the evaporator. Then it is sucked by the compressor, and the
cycle keeps on repeating.

Thermostat
 To control the temperature inside the refrigerator, there is a thermostat, which is
connected to the evaporator directly. There is a round knob inside the refrigerator, using
which you can control the thermostat setting.
 When the desired temperature is reached, it stops the electricity supply automatically to the
compressor. When the temperature falls to a certain level, then it restarts, sending power
supply to the compressor.

Defrost System
 Defrosting the refrigerator helps to remove all the excess ice that gets build up in the freezer. It
can be done both manually by the thermostat button or automatically by the system comprising
of the electric heating and timer
Diffuser
 The diffuser in a refrigerator helps to regulate the flow of cold air from the freezer
compartment into the refrigerator compartment. It has a temperature sensor, which you can
control with the refrigerator thermostat.

External Parts of a Refrigerator and Its Functions

Freezer
 The food items that are to be kept at the freezing temperature are stored in the freezer. The
temperature of a freezer compartment is below zero degrees. It is ideal if you want to make ice
cream, frozen foods, or beverages.
 This is the place where you will find ice for your lemonade.

Door Gasket
 The door gasket is a flexible seal that attaches to the outer edge of the refrigerator door. It
forms an airtight seal around the door when closed. The door gasket prevents warm, moist air
from leaking into the refrigerator compartment.

Light Switch
 The light switch turns the refrigerator lights on and off. As soon as the refrigerator door opens,
it supplies power to the light, and it turns on, and when the door is closed, the power supply
gets interrupted, and it turns off. This way, it saves electricity too.

Shelves
 Shelves of a refrigerator are mostly made of toughened glass. The shelf is the place where you
keep your stuff. They are very sturdy and can hold a lot of weight.

Refrigerator Door
 The refrigerator door has several smaller subsections to keep bottles, eggs, butter, and other
stuff. It maximizes the space in the fridge. The door covers the front of the refrigerator cabinet.

Drain Pan
 The drain pan collects the water from the defrost cycle. It is located next to the compressor, in
the machine compartment. The defrosting process melts frozen ice, and the water that drips
during the process is collected in a tray and then is routed to the drain pan. The drain pan
collects all the condensate.

Water Dispenser
 High-end side by side refrigerators, double/triple door refrigerator comes with this water
dispenser. It lets you drink water without even opening the refrigerator door. Although it
takes up the internal space by a little margin, it’s good to have this feature.
Tools and materials in Ref. & Aircon

Refrigeration tools are used in performing preventive maintenance and repair on air conditioners,
refrigerators, freezers, and automotive air conditioner.

They are as follows:

Tube Cutter – is a refrigeration tool use to cut copper tubing from sizes 1/8” to 1/2” outside diameter.
A larger tube cutter is also available for large tube diameters. Tubes are mark first before cutting.
Slight pressure is applied to the copper tube during cutting. The burr inside the tube is cleaned with
blade reamer.

Flaring Tool – is a refrigeration tool use to spread the copper end outward until a flare is formed. File
and ream the copper tube before flaring. The copper tube is inserted into the flaring block with 30% of
its diameter protruding. Turn the flaring yoke slowly until the flare is completed. Remove copper tube
and inspect for defects.

Swagging Tool – is a refrigeration tool use to expand the inside diameter of a copper tube so that the
resulting diameter is the same as the outside diameter. It is used to join two copper tubes of the same
diameter. Clamp the copper tube by the flaring block so that an 'equal to the outside diameter' of the
copper tube length is to be swagged.
Brazing Torch – is a refrigeration tool use in soldering the joints of two copper tubes together. 800
degrees Fahrenheit is required to solder copper tubing. Map gas is generally used in this application,
although oxygen-acetylene is also popular except they are bulky and heavy. It can reach a temperature
of 3600 degrees Fahrenheit. When brazing copper tube joints, do it in a well-ventilated area. Prolong
inhalation can cause cancer.

Copper Tube Bender – is a copper tube bending refrigeration tool. It has a threesize molded half-
round wheels. The most common sizes are from 1/4 of an inch diameter, to 5/16, then 3/8. Copper
tubes are bent beautifully using this professional bending tool.

Adjustable wrench – is a wrench with an adjustable jaw. A six-inch adjustable wrench is very useful
in the field of refrigeration repair. It can accommodate nuts and bolts' sizes from 1/8 of an inch to 1
inch. It can fit into the tool box easily.

Flat Edge Screw Driver – is a screw driver with a flat driving end. An 8 inch screw driver with a
blade width of 1/4" is the most useful size. It is always a good idea to have a 1/8" blade and a 3/16"
blade around with you.
Philip Screw Driver – is a screw driver with a cross driving end. It is a good idea to have three sizes
of this type also. Buy only good quality philip screw driver because the teeth easily become blunt very
slippery.

Allen Wrench – is an angle hexagonal driving wrench. They are made of hardened steel. You will
need allen key when removing the squirrel caged fan of a window type air conditioner. The circular fan
of an indoor unit is fastened with an allen screw.

Long Nose Plier – is a plier with a long-pointed nose. A 7 inches long nose plier is very useful and is
a good addition to your tool box. You will find the many uses of a long nose plier; from hard to-reach
areas like removing a clip from a fan or holding the copper tube when brazing alone.

Slip Joint Plier – is a mechanical plier with a slip joint in order to adjust the size. Either for fastening
a 1/2" pipe to loosening a 1" water pipe, it is a very handy tool to have. I have with me a 10" slip joint
plier all the time.
Electrical Plier – Insulated plier use by electrician. An 8 inches electrical plier is a must have in your
tool box. There is time when it is necessary to remove a live fuse from a fuse box. Or arranging the
stranded wires.

Pipe Wrench – is a wrench for fastening tubes and pipes. A 12 in pipe wrench must be in your tool
box as well. Sometimes we have to remove a rounded hex nut.

Socket Wrench set – wrench with driving socket. We have the 1/2" drive and the 3/8" drive and the
1/4" drive. I carry all of them when I am on the field. You will need a socket wrench to remove a
remote hex nut or bolt where you have to add extension just to remove it. The set come with a ratchet
which is also a very handy tool.

Nut Drivers – Hand held driver to drive or remove hex nuts or bolts. Mostly applicable to deep down
places where our hand is not able to reach. Straight hand grip type and the T-type drivers are available
for you to choose.
Box Wrench – Hand held box type wrenches. They came in from 1/4 of an inch to 1-1/4 inch size.
Usually they are in combination as far as the size is concern. A practical tool for assembling and
disassembling home air conditioner and automotive air conditioner compressors.

Open Wrench – Open end - hand held wrench. Their sizes are from 1/8 of an inch to 1-1/4 of an inch.
It is most useful when you are removing a machine bolt where access is only 50 to 75 percent, or the
area is restricted that the wrench can make only one - half turn.

Flat File – flat hardened steel with cutting ridges. Used for filing a newly cut copper tube ends to
square it. Or to remove burrs from steel brackets. File surface joints so that they can fit squarely.

Round File – round long hardened steel with cutting ridges. Round file is very useful in enlarging a
hole by filing. Cleaning a rusty steel tube, removing a clogged from a drain hole. Enlarging a flat
washer hole to fit the larger bolt. Or to shape a certain parts through filing. Making prototype spare
parts for hard-to-find spare.

Half Round Files – Half round shaped long hardened steel with cutting ridges. When it is necessary to
make a hole larger where the application of a round file is not practical. The half round side can finish
a curve surface, and the flat side for the flat surface.
Carpenter’s Saw – a hand tool with tooth blade used to cut wood. Fabricating wooden frame for a
window type air conditioner, cutting wooden sticks to be used to elevate an air conditioner unit.
Fabricating elevated stand for a split type stand alone indoor unit.

Tape measure – steel tape measuring device. Put one in your pocket whenever you are going out into
the field. Either you are going to make measurement for the length of the copper tubing you will need
for a certain project, or measuring the volume of a room.

Hack Saw – a hand tool with tooth blade used to cut iron pipes or iron bars, maybe you need to shorten
the length of a certain PVC pipe, or fabricating a bracket for a new air conditioner. Making a new
home air conditioner installation.

Electric Drill Gun – is also a good refrigeration tool a refrigeration mechanic should have. We
measure the size of a drill gun by the size of the chuck. I have with me a 1/2 inch chuck, and it is all I
need in doing different things, like installing a new compressor and I need to make new holes for the
anchor bolts.
 Bench Vise – a refrigeration tool with two jaws for holding works. Most of the time we need a vise to
hold the copper tube so that we can braze the joints correctly. Or we must clamp the machine bolt so
that we can remove the hex nut. Or simply clamp a piece of steel bar so that we can cut it into the size
we need.

Yoke Vise – a pipe vise. It is good to have a yoke vise in your working bench. Yoke vise is a common
refrigeration tool a mechanic should have. Either you are lengthening your water pipes or removing
electrical conduit pipes, a yoke vise clamps the tubing without deforming them.

Gauge Manifold – refrigeration tool pressure gauges. Whenever you are reprocessing a refrigerator, or
replacing a new compressor for a freezer, or charging refrigerant to your automotive air conditioner,
you need a gauge manifold to tell you if you are doing it right.

Refrigeration Cycle

 The refrigeration cycle starts and ends with the compressor. The refrigerant flows into
the Compressor where it is compressed and pressurised. At this point, the refrigerant is a hot gas.
The refrigerant is then pushed to the Condenser which turns the vapour into liquid and absorbs
some of the heat. The refrigerant then proceeds to the Expansion Valve where it expands, losing
pressure and heat.
 The refrigerant coming out of the expansion valve is cold and slow due to the loss of pressure. It
enters the Evaporator in a liquid state where the exchange of heat takes place thus cooling the
load inside the refrigerator. As the gas cools down the load, it absorbs the heat which turns it into
a gas. The gas is then pushed back into the Compressor where it can start the cycle again.