Professional Documents
Culture Documents
Welding
Principles and Practices
Third Edition
Sacks and Bohnart
History of
Welding
Chapter 1
1
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Permission required for reproduction or display.
Overview
1-6
History of Metalworking
1-7
History of Metalworking
1 - 10
Bare Metal Electrode Welding
1 - 12
History of Metalworking
1 - 13
History of Metalworking
1 - 14
Multipass Welds
Pass 1
Pass 3
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1 - 15
History of Metalworking
1 - 16
Shipbuilding
1 - 17
Development of Modern
Welding
• Design of welding machines changed very little
during postwar period
– Done with d.c. current from batteries
• Use of a.c. welding machines occurred in late
1920 and increased in the early 1930s
– First high frequency a.c. industrial machine
introduced in 1936 by Miller Electric Manufacturing
Company
– High rate of metal deposition and absence of arc blow
1 - 18
Inert Gas Welding
1 - 19
GTAW Welding
1 - 20
Tungsten Inert Gas (TIG) Process
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1 - 21
GTAW Welding
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1 - 24
Development of Modern
Welding (continued)
• Rapid changes occurred in 1980s and 1990s
– Exotic multiple gas mixes
– State-of-art electrodes
– Onboard computers
– Robotic welding
• Methods developing that may change way
welds made in future
1 - 25
Processes Involving
Use of the Electric Arc
• Arc spot welding
• Atomic-hydrogen welding
• Electrogas
• Plasma arc welding
• Stud welding
• Submerged arc welding
• Underwater arc welding
1 - 26
Specialized Processes Involving
Use of the Electric Arc
1 - 27
Industry Demand
1 - 28
Welding Associations
1 - 30
Industrial Welding Applications
1 - 31
Resistance Welding
1 - 32
Arc and Gas Welding
1 - 33
Welding Positions
Overhead
Vertical
As well as flat
and horizontal
Miller Electric Mfg. Co.
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1 - 34
Qualifications and Personal
Characteristics
• Welders certified for ability to do work and
work is inspected
• Required to pass periodic qualification tests
• Certifications issued according to kind and
gauge of metal and specific welding process
• Can hold several different certifications
simultaneously
1 - 35
Example of Magnetic-Particle
Testing in Building
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1 - 36
Basic Tasks
• Gas weld
– Attaching proper tip and adjusting welding
regulators for proper volume and gas pressures
• Electric arc welding
– Regulate welding machine for proper welding
current, select proper electrode size and type, and
right shielding gas
• Need steady hand and have good visualization
skills
1 - 37
Master Welder Job Examples
Nooter Corp
Creating Art!
Enrique Vega
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1 - 38
Master Welder
• Master craftsperson
• Able to weld all steels and alloys
– Plus nickel, aluminum, tantalum, titanium,
zirconium, and their alloys and claddings
• Welds of highest quality
• Welds meet requirement of job
– Delicate welding of silver and gold
– Heavy pressure vessels requiring 4-inch plate
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Welding Occupations Requiring
a High School Education
• Welding operator • Welding superintendent
• Welding fitter • Equipment sales
• Combination welder • Sales demonstrator
• Master welder • Sales troubleshooter
• Welding supervisor • Welding instructor
• Welding analyst • Robotics welder operator
• Inspector • Jog or fabrication shop
• Welding foreman owner
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Welding Occupations Requiring
a College Education
• Welding engineer • Technical editor
(metallurgical) • Welding professor
• Welding development • Certified welding inspector
engineer (AWS/CWI)
• Welding research • Corporation executive
engineer • Owner of welding business
• Welding engineer • Sales engineer
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Safety and Working Conditions
• Indoors or outdoors
• Noisy
– Hearing protection needed
• Awkward positions
• Spacious surroundings or
cramped quarters
• High off ground in
scaffolds with safety
harness
The Lincoln Electric Corp.
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1 - 42
Job Hazards
• Fire danger
• Burns (including "sunburn" from electric arcs)
• Noxious fumes from materials vaporized at
high temperatures
• Eyestrain Hazards can be minimized
or eliminated by use
• Welders flash of proper protective
• Electric shock clothing and equipment.
1 - 43
Ways to Stay Current
1 - 44