Welding, Cutting and Brazing

29 CFR 1910.251 & 1926.350

Subpart Q & J

By: Chou Lor, Safety Coordinator

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 Welding, Cutting and Brazing
• Training Objectives
– Three Specific Types of Welding Modules
– Methods of Arc Welding
– Welding Hazards
– Safe Work Practices
– Fire Protection & Prevention
– Proper Ventilation for Welding
– Welding Operators Protection

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 Three Specific Types of Welding
Modules
• In this Welding, Cutting, and Brazing module,
three specific types of welding are covered.
These are listed below:
– Oxygen-fuel gas welding and cutting
– Arc welding and cutting
– Resistance welding

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Oxygen-fuel gas welding & Cutting

• The elements of Oxygen-fuel gas welding

and cutting:
– General Requirements
– Cylinders
– Service Pipe Systems
– Pipe System Protection

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 Oxygen-fuel gas welding and cutting
• General Requirements
– Focuses on using Acetylene Safely
• Flammable
• Unstable
• Cannot be adjusted above 15 psi
•
– Safe Work Practices The pressure adjusting screw:
– Turning clockwise allows the gas
• Blow out cylinder valve –
allows to flow.
Turning counterclockwise
• Turn on cylinder valve first and reduces or stop the gas flow.

then adjust the regulator pressure screw.

• Never stand in front or behind
a regulator when opening the cylinder valve
• Open cylinder valve slowly
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Oxygen-fuel gas welding and cutting
• General Requirements Cont.:
– Safe Work Practices
• Purge oxygen and acetylene passages
• Light the acetylene
• Never use oil or grease
• Do not use oxygen as a substitute for air
• Keep your work area clean

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 Oxygen-fuel gas welding and cutting
• Cylinders
– Cylinder approval and marking
• marked for the purpose of identifying the gas content, with
either the chemical or trade name of the gas

– Storage of cylinders
• Storage area must be well ventilated
• Cylinders must be at least 20 feet from combustibles
• Valves must be closed
• Valve protection must be in place
• Inside storage must be limited to 2,000 cubic feet.
• Cylinders must be stored in upright position
• Oxygen must be at least 20 feet from fuel gas or
5 feet with a 1/2 hour fire barrier
• Separate oxygen from fuel gas

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Oxygen-fuel gas welding and cutting
• Cylinders Cont.:
– Operating Procedures
• Operation must emphasize the absence
of oily or greasy substances. Follow these
rules of operation:
– Cylinders, cylinder valves, couplings,
regulators, hose, and apparatus shall be kept
free from oily or greasy substances.
– Oxygen cylinders or apparatus shall not be
handled with oily hands or gloves.
– A jet of oxygen must never be permitted to
strike an oily surface, greasy clothes, or enter
a fuel oil or other storage tank.

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Oxygen-fuel gas welding and cutting
• Service Pipe Systems
– There are special requirements for service
pipe systems when using oxygen or
acetylene.
• Oxygen
• Acetylene or Acetylene Compounds

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Oxygen-fuel gas welding and cutting

• Pipe System Protection

– The entire service pipe system must be
protected against build-up of excessive
pressure and leaks. This protection is
accomplished with:
• Protective equipment
• Regulators
• Proper hose and hose connections.

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Oxygen-fuel gas welding and cutting
• Pipe System Protection Cont.:
– Protective equipment is divided into the two
categories listed here:
• Pressure Relief Devices
– The pressure relief device should discharge upwards to
a safe location.
– Pressure relief valves are required in fuel-gas piping
systems to prevent excessive pressure build up within
the system.

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Oxygen-fuel gas welding and cutting
• Pipe System Protection Cont.:
– Approved protective equipment shall be
installed in fuel-gas piping to prevent:
• Backflow of oxygen into the fuel-gas supply
system
• Passage of a flash back into the fuel-gas
supply system
• Excessive back pressure of oxygen in the
fuel-gas supply system.
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 Arc Welding and Cutting
• Definition:
– A fusion process wherein the coalescence of
the metals is achieved from the heat of an
electric arc formed between an electrode and
the work.
• Application
• Installation
• Operation & Maintenance

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 Arc Welding & Cutting
• Application
– Applies to a large and varied group of
processes that use an electric arc as the
source of heat to melt and join metals.
• Installation
– Arc welding requires proper installation of
equipment.
– A critical part of installation is ensuring that
proper grounding is completed.

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 Arc Welding & Cutting
• Operation & Maintenance
– All connections to the machine shall be checked
to make certain that they are properly made.
– The work lead shall be firmly attached to the
work.
– Magnetic work clamps shall be free from
adherent metal particles of spatter on contact
surfaces.
– Coiled welding cable shall be
spread out before use to avoid
serious overheating and
damage to insulation.
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 Arc Welding & Cutting
• Operation and Maintenance Cont.:
– During welding operations, cables with splices
within 10 feet (3m) of the holder shall not be
used.
– Welders should not coil or loop welding
electrode cable around parts of their body.
– Cables with damaged insulation or exposed
bare conductors shall be replaced.
– Joining lengths of work and electrode cables
shall be done by the use of connecting means
specifically intended for that purpose.
– The connecting means shall have insulation
adequate for the service conditions.
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 Resistance Welding
• Definition:
– This is a group of fusion welding processes
that use heat and pressure to make the
coalescence.
• The heat comes from electrical resistance to
current flow at the site of the weld.
– The processes include:
• Spot Welding
• Projection Welding
• Seam Welding
Note: FP&M only does spot welding.
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 Resistance Welding
• Spot Welding
– A process typically used in high-volume, rapid
welding applications.
• The pieces to be joined are clamped between two electrodes
under force, and an electrical current is sent through them.
– The advantages of spot welding are many and
include the fact that it is:
• An economical process
• Adaptable to a wide variety of materials including low carbon
steel, coated steels, stainless steel, aluminum, nickel,
titanium, and copper alloys
• Applicable to a variety of thicknesses
• A process with short cycle times
• A robust process
• Tolerant to fit-up variations

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 Welding/Cutting Hazards
• Potential Hazards
– Fires may start by hot materials igniting
nearby combustibles.
– Burns to the operator may occur if unprotected
skin comes into contact with the extremely hot
work.
– Magnetic fields could easily
destroy/disrupt electronic
components, stored data if
not careful.

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 Welding/Cutting Hazards
• Potential Hazards Cont.:
– Metal fumes from vaporizing of the work with the
extremely hot arcs may be inhaled into the worker’s
lungs.
– Certain metals and metal oxide fumes, including zinc,
cadmium and beryllium, produce serious illnesses
when inhaled.
– Fluxes used with welding to create inert atmospheres
at the point of the weld also present inhalation
hazards.
– All welding and cutting must have adequate
ventilation to protect the person doing the welding
and those working around the welding area.
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 Methods of Arc Welding
• Three Types of Welding Methods:
– Tungsten Inert Gas Welding (TIG)
– Gas Metal Arc Welding (MIG)
– Shielded Metal Arc Welding (SMAW)/ Stick
Welding

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 Tungsten Inert Gas Welding (TIG)
• Definition:
– TIG welding is an arc that is formed between
a non-consumable tungsten electrode and
the metal being welded.
– Gas is fed through the torch to shield the
electrode and molten weld pool.
• Benefits:
– Welds with or without filler metal
– Precise control of welding
variables (heat)
– Low distortion
• Shielding Gases:
– Argon
– 2 to 5% Hydrogen
– w/Helium
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Tungsten Inert Gas Welding (TIG)
• Applications
• Most commonly used for aluminum and
stainless steel
• For steel
– Slower and more costly than consumable
welding
– Except for thin sections or where very high
quality is needed

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 Gas Metal Arc Welding (MIG)
• Definition:
– The heat source is formed by creating an
electric arc between the work piece and a wire,
which is fed continuously into the weld pool.
• Benefits:
– Long welds can be made
without starts and stops
– Minimal skill required
– Minimal cleaning of
surface before weld
– Allows welding in all
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 Gas Metal Arc Welding (MIG) Cont.
• Shielding Gases:
• Inert
– Argon, Helium
» Used for aluminum alloys and stainless steels.
• Active
– 1 to 5% Oxygen, 3 to 25% CO2
» Used for low and medium carbon steels

• Applications
• Gas Metal Arc Welding (MIG) is used to weld all
commercially important metals, including steel,
aluminum, copper, and stainless steel.
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 Shielded Metal Arc Welding
(SMAW)/Stick Welding
• Definition:
– Consumable electrode coated with
chemicals that provide flux and shielding
– The filler metal (here the consumable
electrode) is usually very
close in composition to
the metal being welded.

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 Shielded Metal Arc Welding
(SMAW)/Stick Welding
• Benefits
• Simple, portable,& inexpensive
• Self flux provided by electrode
• Provides all position flexibility
• Shielding Gases
• No shield gases added
• Lower sensitivity to Wind

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 Shielded Metal Arc Welding
(SMAW)/Stick Welding Cont.:
• Applications
• Construction, pipelines, shipbuilding, fabrication
job shops.
• Used for: Steels, stainless steels, cast irons.
• Not used for aluminum and its alloys, or
copper and its alloys (energy density is too
high).

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 Cutting
• Definition:
– A stream of oxygen is directed against a piece of
heated metal, causing the metal to oxidize or burn
away.
• Making a Cut
– Mark a line as a guide.
– Turn on acetylene as for welding and light.
– Turn on oxygen adjusting flame to neutral.
– Make sure the oxygen lever flame remains neutral.
– Place metal on the cutting table so metal will fall
clear.
– Flame Types:

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 Brazing
• Definition:
– A process which a filler metal is placed at or between
the faying surfaces, the temperature is raised high
enough to melt the filler metal but not the base metal.
• The molten metal fills the spaces by capillary attraction.
• Torch Brazing
– Oxy-fuel torch with a carburizing flame
– First heat the joint then add the filler metal

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 Safe Work Practices
• Electric & Gas Welding
– Safety Check:
• Ensure electrical cord, electrode holder and
cables are free from defects
– No cable splices within 10 feet of electrode holder.
• Ensure welding unit is properly grounded.
This helps to avoid over heating.
• All defective equipment shall be repaired or
replaced before using.

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 Safe Work Practices
• Electric & Gas Welding Cont.:
– Safety Check:
• Remove all jewelry – rings, watches, bracelets, etc…
• Ensure PPE e.g.. welding hood, gloves, rubber boots or
safety shoes, apron are available and in good
condition.
• Ensure fire extinguisher is charged and available.
• Ensure adequate ventilation and lighting is in place.
• Set Voltage Regulator to Manufacture’s
specifications.
• Avoid electrical shock DON’T wrap cables around any
body part.
• Ensure fittings are tight.

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 Safe Work Practices
• Electric & Gas Welding Cont.:
– Safety Check:
• Inspect hoses for cuts and frayed areas.
• Set gauges to desired PSI.
• Ensure that sufficient PPE is made
available.
• Locate welding screens to protect
employee’s – DON’T block your exit.
• Ensure that adequate ventilation and
lighting are in place.
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 Fire Protection & Prevention
• Fire hazards must be removed, or
– Guards installed, or
– Welding/cutting must NOT take place
• Hot work permit should be used
outside designated areas to ensure
that all fire hazards are controlled
• Use of fire watch
– 1/2 hour after operation ceases

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Fire Protection & Prevention Cont.:
• Welding areas should meet the following
requirements:
– Floors swept & cleared of combustibles 35 ft.
radius of work area.
– Flammable and combustible liquids kept 35 ft.
radius of work area.
– At least one fire extinguisher – on site
– Protective dividers to contain sparks and
slag
• Welding curtains
• Non-combustible walls
• Fire resistant tarps & blankets

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 Proper Ventilation for Welding
• Ventilation
– Proper ventilation can be obtained either naturally or
mechanically.
• Natural Ventilation is considered sufficient for welding and
brazing operations if the present work area meets these
requirements:
– Space of more than 10,000 square feet is provided per welder
– A ceiling height of more than 16 feet.
• Mechanical ventilation options generally fall into two basic
categories.
– Low vacuum system which takes large volumes of air at low
velocities.
– High vacuum system that are captured and extracted fumes as
near to the work as possible.

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 Proper Ventilation for Welding
• Ensure protection from fumes
and gases by one or a
combination of the following:
– Good general ventilation.
– Use of a booth.
– Local exhaust ventilation
on the hand piece.
– Air supply to the helmet.

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 Welding Operators Protection
• Welding involves specialized personal
protection that must be worn every time
you perform welding operations. The
following is a list of basic PPE:
– Fire-resistant gloves
– Aprons
– Safety shoes
– Helmet
– Ultraviolet radiation filter plate (arc welding)
– Goggles with filter lenses

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 Welding, Cutting and Brazing
• Summary
– Major hazards include:
• Fire
• Burns
• Shock
• Toxic Exposure
– Follow proper procedures to prevent fires
– Use appropriate engineering controls
– Wear appropriate PPE

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Any Questions

??
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