1) Introduction to Welding and it’s Safety

Welding is the manufacturing process of joining two or more similar or dissimilar metals by the application of heat,
with or without application of pressure and addition of filler material. The fusion of metal takes place by means of
heat. The heat may be generated either from combustion of gases, electric arc, electric resistance or by chemical
reaction. Welding provides a permanent joint but it normally affects the metallurgy of the components. The welding
is widely used as a fabrication and repairing process in industries. Some of the typical applications of welding
include the fabrication of ships, pressure vessels, automobile bodies, offshore platform, bridges, welded pipes,
sealing of nuclear fuel and explosives, etc.

Advantages of Welding :-
1) All metals can be welded.
2) Light section and heavy section parts can be welded.
3) Due to welding process metals can be joint together at faster rate.
4) Welding can be done in all positions such as Flat, Horizontal, Vertical and Over head.
5) It is used for production and repairing work.
6) There is no wastage of material.
7) Due to welding, its labour cost decreases.
8) Welding provides 100% strength.

Disadvantages of Welding :-
1) Only permanent joints can be made.
2) There is an effect on the work piece due to lot of heat so that distortion takes place in the work piece.

Until the end of the 19th century, the only welding process was forge welding, which blacksmiths had used to join
iron and steel by heating and hammering. Arc welding and oxy fuel welding were among the first processes to
develop late in the century and electric resistance welding followed soon after. Welding technology advanced
quickly during the early 20th century as the world wars drove the demand for reliable and inexpensive joining
methods. Following the wars, several modern welding techniques were developed, including manual methods like
SMAW, now one of the most popular welding methods, as well as semi-automatic and automatic processes such
as GMAW, SAW, FCAW and ESW. Developments continued with the invention of laser beam welding, electron
beam welding, magnetic pulse welding(MPW), and friction stir welding in the latter half of the century. Today, the
science continues to advance. Robot welding is common place in industrial settings and researchers continue to
develop new welding methods and gain greater understanding of weld quality.

History of Welding :-
1803 :- Invention of Welding
1836 :- Invention of Gas welding
1944 :- Invention of Tig welding
1948 :- Invention of Mig welding
1955 :- Invention of Plasma welding

Applications of welding in industrial field :-

1) Welding is used in manufacturing of air craft construction such as air planes, rockets, jet engine etc.
2) It is used in manufacturing of railway engines and coaches etc.
3) It is used in manufacturing of machines and its components etc. Such as lathe machine, crane and its parts.
4) It is used in construction work of different manufacturing plants by using metal angles, channels, ‘I’ section
beams etc.
5) It is used in furniture industry for manufacturing of chairs, tables and bed etc. from metals.
6) It is used in layout of pipe lines used for petroleum industry, chemical plants etc.

Safety
Safety plays an important roll in the workshop. Accidents can occur in the workshop due to lack of knowledge,
carelessness and indiscipline. Due to accidents, fatal can happen to an individual, family and company.
Safety means to do any type of work in a systematic way without any accidents, with confidence and peace of
mind.
Welding is a hazardous undertaking and precautions are required to avoid burns, electric shock, vision damage,
inhalation of poisonous gases and fumes, and exposure to intense ultra violet radiation.
Udayachal High School
Mechanical Technology
Std 9th Welding
1
Many different energy sources can be used for welding, including a gas flame, an electric arc, a laser, an electron
beam, friction, and ultrasound. While often an industrial process, welding may be performed in many different
environments, including in open air, under water, and in outer space.
The safety used in welding department is further classified in to three types.
1) Personal Safety.
2) Workshop Safety.
3) Safety of tools and equipment.

1) Personal Safety :-
a) Don’t wear loose cloths while working. Wear boiler suit and safety shoes.
b) Use hand screen, during welding operation for the protection of eyes.
c) Use leather apron and hand gloves for protecting the body from radiation and burns caused by sparks and flying
globules of molten metal.
d) Before starting welding operation, machine’s safe guard and connections must be fixed.
e) Keep all tools and equipment at a proper place.

2) Workshop Safety :-
a) All welding and thermal cutting operations carried on in confined spaces must be adequately ventilated to
prevent the accumulation of toxic materials, combustible gases, or possible oxygen deficiency.
b) In workshop, there should be proper arrangement of adequate windows, ventilators and lights.
c) In workshop, machines should be properly arranged and earthing must be provided.
d) Welding must be performed in a space entirely screened on all sides, the screens shall be arranged so that no
serious restriction of ventilation exists. It is also used to protect workers from the glare of welding. Welding booth
must be painted with black colour.
e) Fire extinguisher and first aid box must be provided in the workshop.
f) Don’t keep flammable material in the workshop and oil should not spill out on the ground.

3) Safety of tools and equipment:-

a) A welder must have complete knowledge about tools and machines.
b) A proper earthing connection is necessary for all the machines.
c) Machines should not be over heated. If it creates noise, then it must be repaired by skilled mechanic.
d) Use cylinder trolley, for shifting cylinders from one place to another.

First aid :-

First aid is the assistance given to any person suffering a sudden illness or injury with care provided to preserve
life, prevent the condition from worsening, or to promote recovery. It includes initial intervention in a serious
condition prior to professional medical help being available, such as performing CPR while awaiting an ambulance,
as well as the complete treatment of minor conditions, such as applying a plaster to a cut.
First aid is generally performed by the layperson, with many people trained in providing basic levels of first aid
and others willing to do so from acquired knowledge.

Udayachal High School

Mechanical Technology
Std 9th Welding
2
Accidents occur in workshop during welding and it’s remedies.
A) Sharp iron objects and obscure bleeding after Scouring. In this case we have to clean the wound and the apply
Tincture of iodine solution. It is an antiseptic. It is usually 2 to 7% elemental iodine, along with potassium
iodide or sodium iodide, dissolved in a mixture of ethanol and water.
B) Burns from hot objects :- Welders are exposed to extremely hot metals, such as molten metals and hot slag,
causing them to suffer serious burns. There is a chance of infection.
Clean the blister thoroughly and apply proper medicine.
C) Flame retardation :- Due to continuous concentration at the flame and due to smoke of the flame, causes eye
pain. In this case apply rose water in your eyes.
D) Electric shock :- Welding processes that use electricity pose both obvious and subtle hazards of electric
shock - which can be fatal. An electric shock is a dangerous and painful physiological effect caused by
the passing of an electric current through the body of a human or animal. Due to electrical shock, the victim’s
breathing may stop and the body may appear stiff. In giving first aid first the electrical contact is broken as
quickly as possible. This must be done with care so that the rescuer does not have exposure to the current. If the
victim has stopped breathing and has no pulse, cardiopulmonary resuscitation is begun immediately.
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Exercise :-
1) What is welding?
2) State the importance of welding.
3) Write down the applications of welding in various industries.
4) What is safety ?
5) State different types of safety used in welding department.
6) Explain personal safety used in welding department.
7) Explain workshop safety used in welding department.
8) Explain safety of tools and equipment used in welding department.
9) What is First aid?

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Udayachal High School

Mechanical Technology
Std 9th Welding
3