Lesson 1: Fundamentals of SMAW process
1930s-1940s: The 1930s and 1940s saw significant advancements in the quality and
1.1 History of Welding
The Shielded Metal Arc Welding (SMAW) process, also known as stick welding, has a rich
history that spans over a century. Here's a brief overview of the key developments in the
history of SMAW welding:
1. Early 20th Century: The roots of SMAW can be traced back to the early 20th
century. Prior to the development of coated electrodes, manual welding processes
involved using bare metal rods, often in conjunction with a flux applied separately.
However, these processes were less efficient and produced welds of varying quality.
2. 1910s-1920s: The true breakthrough in SMAW came with the introduction of coated
electrodes. In the early 1910s, Oscar Kjellberg, a Swedish engineer, developed the
first practical coated electrode. These electrodes had a flux coating that served
multiple purposes, including creating a protective atmosphere around the arc,
adding alloying elements to the weld, and producing a slag layer to protect the
molten metal.
3.
availability of coated electrodes. The American Welding Society (AWS) established
electrode classification systems to help standardize electrode types based on their
properties and applications. This period also saw improvements in electrode
manufacturing techniques, resulting in more consistent and reliable performance.
4. World War II: The demand for efficient welding techniques during World War II
accelerated the development of SMAW. The process was widely used for
shipbuilding, aircraft manufacturing, and other military applications. The simplicity
and versatility of SMAW made it suitable for field welding and repair work.
5. Post-World War II Era: After the war, SMAW continued to be a popular welding
process for various industries. Advances in electrode composition and flux
technology further improved the process's performance, allowing for better control
of weld properties, such as penetration, bead appearance, and mechanical strength.
6. 1960s-1970s: The 1960s and 1970s brought improvements in electrode coatings and
core wire materials. These advancements led to better arc stability, reduced spatter,
and improved weld bead quality. The introduction of low-hydrogen electrodes
significantly reduced the risk of hydrogen-induced cracking in welds, making SMAW
suitable for critical applications.
 7. Modern Era: SMAW remains a fundamental and widely used welding process,
especially in situations where other welding methods are less practical, such as
outdoor or remote locations. While more automated and advanced welding
processes have emerged, SMAW continues to have a place in industries such as
construction, maintenance, and infrastructure repair.
Over the years, SMAW has benefited from advancements in electrode technology,
equipment design, and welding techniques. While other welding processes have gained
prominence, SMAW's simplicity, versatility, and ability to produce high-quality welds in
challenging environments ensure its continued relevance in the world of welding.
1.2. Principle of SMAW
Shielded Metal Arc Welding (SMAW), also known as manual metal arc welding or stick
welding, is a commonly used welding process that involves creating an arc between a flux-
coated electrode and the workpiece. The electrode is consumed during the welding process,
providing the filler metal and the flux necessary to create a strong bond between the pieces
being welded. Here are the basic principles of the SMAW process:
1. Electrode and Polarity: In SMAW, a consumable electrode is used, which is coated
with a flux that provides various functions, including protection from atmospheric
contamination, slag formation, and the addition of alloying elements. The electrode
can be either positive or negative, depending on the type of electrode and the
desired characteristics of the weld joint. When the electrode is connected to the
positive terminal of the power source, it is known as direct current electrode
positive (DCEP) or reverse polarity. When connected to the negative terminal, it is
known as direct current electrode negative (DCEN) or straight polarity.
2. Arc Formation: The operator strikes an arc by bringing the electrode into contact
with the workpiece and then quickly pulling it back a short distance to establish a
gap. As the electrode is lifted, the electrical resistance between the electrode and
the workpiece generates intense heat, causing the electrode tip to melt and form an
electrically conductive arc. The heat of the arc melts the base metal and the
electrode, creating a weld pool.
3. Heat Generation and Melting: The heat generated by the arc melts both the base
metal and the electrode, forming a molten weld pool. The filler metal from the
electrode is transferred across the arc into the weld pool. The flux coating on the
electrode produces a protective shielding gas and slag layer that prevents
atmospheric contamination and oxidation of the molten metal.
4. Filler Metal Addition: As the electrode melts, the filler metal is deposited into the
weld pool. The composition of the electrode's filler metal contributes to the
mechanical properties and characteristics of the final weld joint. The operator
controls the size of the weld bead and the amount of filler metal added by
manipulating the arc length and the angle of the electrode.
5. Slag Formation and Protection: The flux coating on the electrode produces a layer
of slag that covers the weld bead as it cools. The slag serves multiple purposes,
including acting as a thermal barrier to slow down the cooling rate of the weld
metal, protecting the molten metal from atmospheric gases, and allowing impurities
and oxides to rise to the surface, where they can be removed after welding.
6. Weld Solidification: As the weld cools, the molten metal solidifies and fuses the
base materials together. The slag layer solidifies on top of the weld bead. Once the
weld has cooled sufficiently, the slag can be chipped away, revealing the finished
weld joint.
SMAW is a versatile welding process that can be used in various positions and is well-suited
for outdoor and remote welding applications. However, it requires skill and experience on
the part of the welder to control the arc length, electrode angle, and travel speed to achieve
high-quality welds.

1.3. How electric arc produce

An electric arc is produced when a high-voltage electrical current passes between two
conductive materials through a gap of air or other gaseous medium. The intense heat
generated by the electric arc can cause the air or gas to ionize, forming a highly conductive
plasma that sustains the arc. This process is used in various applications, including welding,
cutting, lighting, and more. Here's a breakdown of how an electric arc is produced:

1. Voltage Difference: To create an electric arc, there must be a significant difference

in voltage (potential difference) between two conductive materials. This voltage
difference is typically generated by a power source, such as a transformer,
generator, or battery.

2. Conductive Materials: The materials between which the arc will be produced are
typically referred to as the "electrodes." One electrode is connected to the positive
terminal of the power source (anode), while the other electrode is connected to the
negative terminal (cathode).

3. Air or Gaseous Medium: There needs to be a gap or space between the two
electrodes through which the electrical current can flow. This gap is usually filled
with air or another gas. At normal conditions, air is a poor conductor of electricity.
However, as the voltage increases, the electrical field becomes strong enough to
strip electrons from air molecules, ionizing them and turning the air into a
conductive plasma.
Lesson 2. Major Hazard identification in the workplace  Flammable Materials: If welding is conducted near flammable materials without
proper precautions, the risk of fires and explosions is heightened.

 Electrical Equipment: If proper lockout/tagout procedures are not followed, the risk
of electric shock when working on electrical equipment increases.

 Sharp Tools: If workers are not using appropriate personal protective equipment,
the risk of cuts or injuries from sharp tools is greater.

In summary, the hazard is the potential source of harm, and the risk is the likelihood and
severity of harm occurring when exposed to that hazard. Understanding and managing both
hazards and risks are essential for creating a safe work environment in a welding shop. This
Hazard: A hazard in a welding shop is a potential source of harm or danger that exists within
involves implementing controls, safety measures, and appropriate training to reduce risks
the environment, equipment, or processes. It is something that has the inherent potential to
and prevent harm to workers and the surrounding environment.
cause harm, regardless of whether someone is actually exposed to it. In a welding shop,
hazards can include:

 Welding Fumes: The fumes generated during welding contain hazardous metal 2.1. Mechanical hazard
particles, such as chromium and manganese, which can be harmful if inhaled.
A mechanical hazard in a welding shop refers to any
 UV Radiation: Intense ultraviolet (UV) radiation produced during welding can cause danger or risk that arises from machinery,
skin burns and eye damage if proper protection is not used. equipment, or physical processes that can cause harm
or injury to workers. These hazards often involve
 Flammable Materials: Presence of flammable materials, like chemicals or oily rags,
moving parts, heavy machinery, and various
that can catch fire from welding sparks and heat.
mechanical processes that are common in welding and
 Electrical Equipment: Live electrical equipment and circuits that can lead to electric metalworking environments. Examples of mechanical
shock if not properly handled. hazards in a welding shop include:
 Sharp Tools: Tools and equipment with sharp edges or moving parts that can cause 1. Moving Machinery: Exposure to moving parts of
cuts, abrasions, or injuries. machinery or equipment, such as rotating wheels, belts, gears, and pulleys, which
can lead to entanglement, caught-in, or crushing hazards.
Risk: Risk, on the other hand, involves the likelihood and severity of harm occurring when
someone is exposed to a hazard. It takes into account various factors that influence the 2. Heavy Equipment: Working with heavy machinery or tools, such as cranes, forklifts,
potential outcome of an encounter with a hazard. In the welding shop example: and hoists, which can result in collisions, tip-overs, or falling objects.

 Welding Fumes: If welders are consistently exposed to welding fumes without 3. Mechanical Cutting and Grinding Tools: Using tools like grinders, cutoff saws, and
proper ventilation or respiratory protection, there is a higher risk of respiratory shears, which can cause injuries if not operated properly, leading to cuts, abrasions,
problems, lung diseases, and long-term health effects. or punctures.

 UV Radiation: If welders do not wear appropriate eye and skin protection, the risk
of developing "arc eye" or skin burns due to UV radiation exposure increases.
 4. Material Handling: Lifting, carrying, or moving heavy metal sheets, components, or 2.2. Electrical hazards
materials manually, which can lead to strain, musculoskeletal injuries, or dropped
objects.

5. Presses and Forming Equipment: Operating machinery like presses and formers
that bend, shape, or deform metal, posing pinch points, crushing hazards, or the risk
of material ejection.

6. Welding Equipment: Handling welding machines and torches with hot surfaces and
electrical components, which can result in burns, electric shocks, or fire hazards.

7. Abrasive Blasting and Cleaning Equipment: Working with equipment that uses
abrasive materials to clean or prepare surfaces, which can generate airborne
particles and pose respiratory hazards.

8. Mechanical Failure: Unexpected breakdowns or malfunctions of machinery,

equipment, or tools, which can cause accidents due to sudden movement, release
of stored energy, or other failures.

To mitigate mechanical hazards in a welding shop, employers and workers should

implement proper safety measures: Electrical hazards in welding refer to potential dangers and risks associated with the use of
electricity in welding and metalworking processes. These hazards arise due to the presence
 Provide adequate training and instruction on the safe use of machinery and
of electrical currents, high voltages, and the combination of electricity with other elements
equipment.
like water and metal. Electrical hazards can pose significant risks to both the welders and
 Use appropriate personal protective equipment (PPE) such as gloves, safety glasses, the equipment if proper safety measures are not in place. Examples of electrical hazards in
and helmets. welding include:

 Establish and enforce lockout/tag out procedures to control hazardous energy
sources.
 Regularly inspect and maintain machinery and tools to prevent malfunctions.
 Clearly mark hazardous areas and moving parts with signage and warnings.
 Implement machine guarding to prevent contact with moving parts.
1. Electric Shock: Exposure to live electrical currents can lead to electric shock, which
can result in injuries ranging from mild discomfort to severe burns, cardiac arrest, or
even death.
2. Arc Flash: During welding, an intense arc is generated that emits heat, light, and
radiation. An arc flash can cause burns and potential damage to the eyes and skin if
adequate protection is not worn.

 Encourage safe material handling practices and provide mechanical assistance as 3. Electric Arc Welding Machines: Operating welding machines without proper
needed. training can increase the risk of electric shock and arc flash incidents.

Overall, recognizing and addressing mechanical hazards in a welding shop is crucial to 4. Faulty Equipment: Using damaged or improperly maintained welding equipment
creating a safe and secure working environment for all employees. can result in electrical hazards and malfunctions.
 5. Inadequate Grounding: Improper grounding or the absence of grounding can lead
to electric shock hazards for both the welder and the equipment.
6. Wet Conditions: Welding in wet environments or with wet hands increases the risk
of electric shock due to enhanced conductivity.
7. Overloading Circuits: Overloading electrical circuits by connecting multiple
machines or devices to a single outlet can result in tripped circuit breakers, electrical
fires, or equipment damage.
8. Extension Cords: Using damaged or incorrect extension cords can cause
overheating, short circuits, and electrical fires.
To mitigate electrical hazards in welding, employers and workers should follow these safety
measures:
 Provide proper training to welders on electrical safety protocols and equipment
operation.
 Use well-maintained and properly grounded welding equipment.
 Inspect welding cables, connectors, and plugs for damage before each use.
 Ensure proper ventilation and remove flammable materials from the welding area
to prevent fires.
 Wear appropriate personal protective equipment (PPE), including insulated gloves,
safety glasses, and flame-resistant clothing.
 Use welding curtains or screens to contain sparks and protect others from exposure
to the arc.
 Avoid using extension cords unless they are specifically designed for welding
applications.
 Implement lockout/tag out procedures to control hazardous energy sources during
maintenance or repairs.
Overall, understanding and addressing electrical hazards in welding are vital for creating a
safe work environment and preventing accidents and injuries.
2.3. Chemical hazards
Chemical hazards in welding refer to potential dangers and risks associated with exposure to
hazardous chemicals and substances that are generated during welding and related
processes. These hazards can result from the use of various materials, coatings, gases, and
fumes that are emitted or produced when welding metals. Exposure to these chemicals can
lead to a range of health effects, from short-term irritation to long-term respiratory and
systemic issues. Examples of chemical hazards in welding include:
1. Welding Fumes: Inhalation of welding fumes containing metal oxides, such as
manganese, chromium, nickel, and zinc, which can lead to respiratory issues, metal
poisoning, and other health problems.
2. Gases: Exposure to gases like nitrogen dioxide, ozone, and carbon monoxide that
are generated during welding, causing respiratory irritation and potentially leading
to suffocation or poisoning.
3. Fluxes and Coatings: The use of fluxes, coatings, and anti-spatter agents can release
hazardous fumes containing toxic compounds and metals when they vaporize
during welding.
4. Paints and Solvents: Welding near painted surfaces or using solvents for cleaning
can release harmful chemicals and gases.
5. Lead and Cadmium: Welding on surfaces coated with lead or cadmium-containing
paints can release toxic fumes that, when inhaled, can cause lead and cadmium
poisoning.
 6. Brazing and Soldering: Similar to welding, brazing and soldering processes can 2.4. Fire Hazard
generate hazardous fumes, particularly when using fluxes containing harmful
compounds.

To mitigate chemical hazards in welding, employers and workers should follow these safety
measures:

 Provide proper training to welders on the risks of chemical exposure and the use of
protective measures.

 Ensure adequate ventilation in the welding area to control the dispersion of fumes
and gases.

 Use local exhaust ventilation systems to capture and remove welding fumes at the
source.

 Provide appropriate respiratory protection, such as respirators, when working in
confined or poorly ventilated spaces.
 Use welding techniques and materials that generate fewer fumes and toxic
substances.
 Use less toxic alternatives when possible, such as low-fume or low-hazard welding
consumables.
 Wear appropriate personal protective equipment (PPE), including respiratory
protection, eye protection, and gloves.
 Implement proper hygiene practices, such as washing hands and face after welding
tasks.
Regular monitoring of the welding environment and conducting air quality assessments can
also help identify potential chemical hazards and ensure the safety of workers. Overall,
understanding and addressing chemical hazards in welding are essential for protecting the
health and well-being of welders and those working in related fields.
A fire hazard in welding refers to the potential risks and dangers associated with fire
incidents that can occur during welding and related processes. These hazards arise due to
the presence of open flames, sparks, and high temperatures in welding operations, which
can ignite flammable materials, gases, and surroundings. Fire hazards in welding pose
significant risks to both the welders and the surrounding environment if proper safety
measures are not in place. Examples of fire hazards in welding include:
1. Sparks and Hot Particles: During welding, sparks, molten metal droplets, and hot
particles can be ejected, potentially igniting flammable materials or causing burns.
2. Ignition of Flammable Materials: Welding near flammable materials, such as paper,
cloth, chemicals, and oily surfaces, can lead to rapid fires and explosions.
3. Ignition of Combustible Dust: In environments with combustible dust, welding
sparks can ignite dust particles in the air, leading to dust explosions.
4. Gases and Vapors: Flammable gases and vapors in the welding area can ignite when
exposed to the heat and open flames produced during welding.
5. Welding Near Ignition Sources: Welding near ignition sources, such as electrical
equipment, open flames, or heated surfaces, increases the risk of fire incidents.

To mitigate fire hazards in welding, employers and workers should follow these safety
measures:
  Clear the welding area of flammable materials, liquids, and dust before starting
work.
 Use welding screens or curtains to prevent sparks and hot particles from spreading.
 Have a fire extinguisher with the appropriate rating readily available in the welding
area.
 Keep a fire watch or monitor the area after welding to ensure no smoldering or
ignition sources remain.
 Ensure proper ventilation to reduce the concentration of flammable gases and
fumes.
 Avoid welding on containers or equipment that previously held flammable
substances without proper cleaning.
 Store flammable materials in designated areas away from the welding work zone.
 Use non-combustible or flame-resistant materials whenever possible.
In addition to these measures, it's essential to have a well-developed emergency response
plan in place that includes procedures for handling fires, evacuations, and communication in
case of a fire incident. Proper training and awareness among workers about fire hazards and
prevention can significantly reduce the risk of fire-related accidents in welding
environments.
2.5. Industrial Health Hazard
Industrial health hazards in welding refer to potential risks and dangers that can adversely
affect the health and well-being of workers in welding and metalworking environments.
These hazards arise from exposure to various harmful agents, substances, and conditions
that can lead to short-term or long-term health effects. It's crucial to recognize and address
these hazards to ensure the safety and health of workers in industrial settings. Examples of
industrial health hazards in welding include:
1. Welding Fumes: Inhaling welding fumes containing metal particles and compounds,
such as chromium, manganese, and nickel, can lead to respiratory issues, lung
diseases, and long-term health problems.
2. Respiratory Irritants: Exposure to gases like ozone and nitrogen dioxide generated
during welding can cause respiratory irritation and exacerbate conditions like
asthma.
3. Sensitizers: Welding can release substances that act as respiratory sensitizers,
causing allergic reactions and asthma in some individuals.
4. Skin Irritants: Contact with welding dust and splatter can lead to skin irritation and
dermatitis.
5. Noise Exposure: Welding processes can produce high levels of noise that can lead to
noise-induced hearing loss if proper hearing protection is not used.
6. UV Radiation: Intense ultraviolet (UV) radiation emitted during welding can cause
skin burns and eye damage, commonly known as "arc eye" or "welders' flash."
7. Ergonomic Hazards: Improper work positioning and repetitive motions during
welding can lead to musculoskeletal disorders.
8. Heat Stress: Working in hot welding environments can lead to heat-related illnesses
if proper hydration and rest are not maintained.
To mitigate industrial health hazards in welding, employers and workers should implement
these safety measures:
 Provide proper training on the risks of exposure to welding fumes, gases, and other
hazardous agents.
 Ensure proper ventilation in the welding area to control the dispersion of fumes and
gases.
  Use local exhaust ventilation systems to capture and remove welding fumes and
gases at the source.

 Provide appropriate respiratory protection, such as respirators, when necessary.

 Use flame-resistant clothing, gloves, and other personal protective equipment (PPE)
to minimize skin contact and UV radiation exposure.

 Implement proper hygiene practices, such as washing hands and face after welding
tasks.

 Conduct regular health screenings and monitoring for workers exposed to welding
hazards.

 Provide ergonomic training and promote proper work techniques to prevent

musculoskeletal disorders.

 Provide hearing protection to prevent noise-induced hearing loss.

Overall, recognizing and addressing industrial health hazards in welding are crucial for
safeguarding the health and well-being of workers and ensuring a safe and productive
working environment.
Lesson 3: Welding tools and equipment
Welding tools and equipment are essential components used in various welding processes
to join metals and create strong, durable connections. These tools facilitate the fusion of
materials through heat, pressure, or a combination of both. Different types of welding
require specific tools and equipment to ensure safe and efficient operations. Here are some
common welding tools and equipment used in welding shops:
1. Welding Machine: The welding machine is the core equipment that provides the
electrical current needed to generate the welding arc. Different types of welding,
such as arc welding, MIG welding, and TIG welding, require specific welding
machines.
2. Welding Helmet: A welding helmet is worn by the welder to protect the eyes and
face from intense light, sparks, and UV radiation generated during the welding
process. It features a dark visor that automatically darkens when the arc is struck.
3. Welding Gloves: Welding gloves are designed to protect the hands from heat,
sparks, and molten metal during welding. They are made from heat-resistant
materials and provide a barrier against burns and injuries.
4. Welding Jacket: A welding jacket is a flame-resistant garment that covers the upper
body and arms, providing protection from sparks, spatter, and radiant heat.
5. Welding Apron: A welding apron offers additional protection for the lower body,
legs, and clothing from sparks and heat. It is often made from the same flame-
resistant material as welding jackets.
6. Welding Respirator: A welding respirator is a respiratory protection device that
filters out welding fumes and particles from the air, preventing inhalation of harmful
substances.
7. Welding Curtains and Screens: These protective barriers help contain sparks,
spatter, and UV radiation within the welding area, preventing them from spreading
to other parts of the workshop.
8. Welding Clamps and Magnets: Clamps and magnets are used to hold workpieces
securely in place during welding, ensuring accurate and stable positioning.
9. Chipping Hammer and Wire Brush: After welding, these tools are used to remove
slag, spatter, and other debris from the weld surface, ensuring a clean and smooth
finish.
10. Electrodes and Consumables: Different welding processes require specific
consumables, such as electrodes, wires, and filler metals, which are melted to
create the weld joint.
11. Welding Table: A welding table provides a stable and flat surface for positioning and
securing workpieces during welding, fabrication, and assembly.
12. Welding Pliers: These pliers are designed with heat-resistant handles and
specialized jaws for tasks like cutting and shaping welding wire and electrodes.
13. Welding Ground Clamp: The ground clamp connects the welding machine to the
workpiece, completing the electrical circuit and ensuring a stable welding arc.
14. Welding Goggles: Similar to welding helmets, welding goggles protect the eyes from
intense light, sparks, and UV radiation. They are smaller and more lightweight,
suitable for certain welding applications.
15. Gas Cylinders: Gas cylinders contain shielding gases or mixtures used in welding
processes like MIG and TIG welding to protect the weld pool from atmospheric
contamination.
16. Welding Cart: A welding cart provides a convenient way to transport welding
equipment, gas cylinders, and consumables around the workshop.

3.1. Select and use hand tools
Hand tools play a crucial role in various tasks, including welding, by providing precision,
control, and versatility. Here are some essential hand tools commonly used in welding and
metalworking:
1. Chipping Hammer: Used to remove slag and spatter from welds and work pieces.
2. Wire Brush: Helps clean and prepare the metal surface before welding.
3. Welding Pliers: Specifically designed for tasks like cutting and shaping welding wire
and electrodes.
4. Welding Clamps: Used to secure work pieces in position during welding.
5. Center Punch: Creates a starting point for drilling or marking on metal surfaces.
6. Scribe: Used to mark lines and measurements on metal surfaces.
7. Vice Grips (Locking Pliers): Provides a secure grip on materials during welding and
other tasks.
8. Hand Files: Used for shaping and smoothing metal edges and surfaces.
9. Tape Measure: Essential for accurate measurements during fabrication and welding.
10. Combination Square: Used to mark and measure angles, ensuring precise cuts and
welds.
11. Adjustable Wrench: Used for tightening and loosening nuts and bolts.
12. Hacksaw: Used for cutting metal and other materials.
13. Needle Files: Small files for intricate shaping and finishing.
14. Scratch Awl: Creates small indentations or marks on metal surfaces.
15. Snips: Used for cutting sheet metal and other thin materials.
16. Bolt Cutters: Designed for cutting bolts, chains, and other heavy-duty materials.
17. Claw Hammer: Used for general tasks, such as shaping and removing nails.
18. Cold Chisel: Used for cutting, shaping, and chipping metal.
19. Ball Peen Hammer: Used for shaping and forming metal.
20. Welding Magnet: Holds ferrous metal pieces at various angles during welding.
These hand tools are essential for performing various tasks in welding and metalworking,
from preparing workpieces to welding and finishing. Proper care, maintenance, and safe
usage of these tools are vital for ensuring efficient and high-quality work while minimizing
the risk of accidents or injuries.
3.3. Maintain hand tools
Maintaining hand tools is essential to ensure their longevity, performance, and safety during
welding and other tasks. Regular maintenance can help prevent wear, damage, and
accidents. Here are some tips for maintaining hand tools:
1. Clean Tools: After each use, clean tools thoroughly to remove dirt, debris, and
residues. Use a wire brush, cloth, or compressed air to clean hard-to-reach areas.
2. Oil and Lubricate: Apply a light coat of oil to metal parts of tools to prevent rust and
corrosion. Lubricate moving parts, such as hinges and pivot points, with appropriate
lubricants.
3. Store Properly: Keep tools in a dry, clean, and organized storage area. Use
toolboxes, racks, or pegboards to prevent tools from getting damaged or lost.
4. Inspect Regularly: Periodically inspect tools for signs of wear, damage, or defects.
Check handles, grips, cutting edges, and moving parts for any issues.
5. Sharpen Cutting Edges: Sharpen cutting tools, such as chisels and snips, when they
become dull. Use sharpening stones or files to restore the edges.
6. Replace Worn Parts: Replace worn or damaged parts, such as handles or grips, to
maintain tool functionality and user comfort.
7. Prevent Rust: To prevent rust, store tools in a dry environment and apply a light
coat of rust-preventive oil. For particularly susceptible tools, consider using rust-
resistant coatings.
8. Inspect Handles: Check handles for cracks, splinters, or signs of wear. Replace
damaged or worn handles to ensure a secure grip and safe usage.
 9. Keep Cutting Edges Sharp: Regularly maintain sharp cutting edges on tools like
chisels, saws, and snips to ensure clean and efficient cuts.

10. Check Moving Parts: Inspect hinges, locks, and other moving parts to ensure
smooth operation. Apply lubricants if needed.

11. Tighten Fasteners: Check screws, bolts, and other fasteners to ensure they are tight.
Loose fasteners can affect tool performance and safety.

12. Follow Manufacturer Recommendations: Adhere to the manufacturer's guidelines

for maintenance and storage to maximize tool lifespan.

13. Use Protective Cases: For portable or high-value tools, consider using protective
cases or sleeves to prevent physical damage during transport and storage.

14. Safety First: Always wear appropriate personal protective equipment (PPE) when
working with tools. Follow proper techniques and precautions to prevent accidents.

15. Training: Train workers on proper tool usage, care, and maintenance to ensure
consistency and safety.

Properly maintained hand tools not only improve work efficiency but also contribute to a
safer working environment. Regularly dedicating time to inspect, clean, and maintain tools
can save time and money in the long run by preventing accidents, reducing downtime, and
extending the life of the tools.
 Review Questions
Lesson 1: Fundamentals of SMAW Process
1.1 History of Welding:
1. What key development in the early 20th century preceded the use of coated
electrodes in manual welding processes?
2. Who is credited with developing the first practical coated electrode, and what were
the functions of the flux coating?
3. How did the demand for efficient welding techniques during World War II impact
the advancement of SMAW?
4. Explain the significance of electrode classification systems established by the
American Welding Society (AWS) during the 1930s-1940s.
5. In what industries does SMAW continue to find relevance in the modern era,
despite the emergence of more advanced welding processes?
1.2 Principle of SMAW:
1. Describe the role of electrode polarity in Shielded Metal Arc Welding (SMAW) and
the differences between direct current electrode positive (DCEP) and direct current
electrode negative (DCEN).
2. How is an arc formed in SMAW, and what factors influence the creation of a stable
arc?
3. What are the functions of the flux coating on the electrode during the welding
process?
4. How does the filler metal contribute to the final weld joint's mechanical properties?
5. What purpose does the slag layer serve in the SMAW process, and why is it
important for achieving high-quality welds?
1.3 How Electric Arcs Are Produced:
1. What conditions are necessary for the creation of an electric arc?
2. What role do conductive materials play in the production of an electric arc?
3. How does the ionization of air or gas contribute to the sustainability of an electric
arc?
4. Provide examples of applications other than welding that utilize electric arcs.
5. Explain why air, under normal conditions, is a poor conductor of electricity and how
it transforms into a conductive plasma during the ionization process.
Lesson 2: Major Hazard Identification in the Workplace
2.1 Mechanical Hazard:
1. Define a mechanical hazard in the context of a welding shop and provide examples
of moving machinery-related hazards.
2. How can heavy equipment in a welding shop pose risks to workers, and what
measures should be taken to mitigate these risks?
3. Explain the term "pinch point" and how it relates to mechanical hazards in welding.
4. What is the purpose of machine guarding, and why is it important in preventing
mechanical hazards?
5. Describe two potential risks associated with the use of welding equipment and
torches.
2.2 Electrical Hazards:
1. What is the primary danger posed by electric shock in welding, and how can it
impact a welder?
2. How does an arc flash differ from electric shock, and what protective measures are
necessary to prevent arc flash injuries?
3. Explain the significance of proper grounding in welding to prevent electrical hazards.
4. Describe two situations or conditions that can lead to an increased risk of electrical
hazards in a welding shop.
5. List three types of personal protective equipment (PPE) that are essential for
protecting against electrical hazards during welding.

2.3 Chemical Hazards:
1. Define chemical hazards in welding and provide an example of a hazardous
substance generated during welding.
2. How can welding fumes containing metal oxides impact the health of welders, and
what potential long-term effects might result from exposure?
3. Identify two gases that can be generated during welding and their potential health
effects on workers.
4. What is the purpose of using low-fume or low-hazard welding consumables, and
how do they contribute to reducing chemical hazards?
5. Name three safety measures that can be taken to mitigate chemical hazards in a
welding shop.
2.4 Fire Hazard:
1. What are some potential ignition sources in welding that can lead to fire hazards?
2. How can sparks, molten metal droplets, and hot particles contribute to fire hazards
in welding?
3. What precautions should be taken to prevent fires when welding near flammable
materials?
4. How can the presence of combustible dust in the environment increase the risk of
fire hazards during welding?
5. Provide three measures that employers and workers can implement to mitigate fire
hazards in a welding shop.
2.5 Industrial Health Hazard:
1. Define industrial health hazards in welding and provide an example of a health
hazard associated with welding fumes.
2. How can exposure to welding fumes containing metal particles impact respiratory
health, and what are some long-term health effects?
3. Explain the term "arc eye" and how it relates to UV radiation exposure in welding.
4. Describe two types of personal protective equipment (PPE) that can help minimize
the risks of industrial health hazards during welding.
5. List three safety measures that employers can implement to mitigate industrial
health hazards in a welding environment.
Lesson 3: Welding Tools and Equipment
3.1 Select and Use Hand Tools:
1. Explain the purpose of a chipping hammer in welding and describe when it would be
used.
2. How do welding clamps contribute to the welding process, and why are they
important for achieving accurate welds?
3. Compare the functions of a wire brush and a welding plier in the context of welding
preparation.
4. What is the primary role of a welding magnet, and how can it be beneficial during
welding operations?
5. Why is a center punch used, and what does it help create on a metal surface?
3.3 Maintain Hand Tools:
1. List three steps you would take to properly maintain hand tools after using them in
welding tasks.
2. How does regular maintenance of hand tools contribute to workplace safety?
3. Explain the importance of sharpening cutting edges on hand tools and describe the
process of sharpening.
4. How can rust affect the functionality of hand tools, and what preventive measures
can be taken to prevent rust?
5. What should workers do if they notice a crack or splinter in the handle of a hand
tool? Why is this important?