Arc weldingbasics

2
Unit Topics
• Topics included in this
overview are:
– Introduction
 What is Arc Welding?
 Why is Welding Important?
 Why Learn to Weld?
– Careers in Welding
– The American Welding
Society (AWS)
– Welding Safety
– Basic Electricity
– Welding Fundamentals
– Welding Certification

3
Objectives
• Upon successful completion of this unit of study, you will
be able to …
– Identify definitions and terminology associated with welding
– Demonstrate safe working habits in the welding environment
– Name the parts and types of welds and weld joints
– Interpret basic welding symbol information
– Identify opportunities available to welders

5
What is Arc Welding?
• Arc welding is most commonly used to join two
pieces of metal
– The welder creates an electric arc that melts the
base metals and filler metal (consumable) together
so that they all fuse into one solid piece of metal
Steel Pipe – Tack
Welded
Root Pass or
“Stringer Bead”
Final weld after
several beads are
made

6
Why is Welding Important?
• Many things around us are welded …
– Pipelines that bring fresh water
– Towers that carry electricity to houses
– Cars and buses that take people where they need to go

7
Why Learn to Weld?
• Welding is so HOT …. it’s COOL!
– Welding can help build a successful career so you
can get the things you want in life
– Skilled welders are in demand – people use things
that are welded everyday!
– Welding can be fun and safe
– It is challenging and high-tech

8
Basic Steps of Arc Welding
• Prepare the base materials: remove paint and rust
• Choose the right welding process
• Choose the right filler material
• Assess and comply with safety requirements
• Use proper welding techniques and be sure to protect
the molten puddle from contaminants in the air
• Inspect the weld

9
The American Welding Society
• Who is the AWS?
– American Welding Society
– It is a non-profit organization whose membership includes:
 Individuals
 Students
 Companies
• What do they do?
– Their purpose is to:
 Advance the science, technology, and application of welding and allied
processes including: joining, brazing, soldering, cutting, and thermal spray
 Standardize classification of electrode and base material codes
 Standardize process procedures
 Provide welding certification

11
Careers in Welding
• Engineering
• Racing
• Industrial Sales
• Farm Repair and Fabrication
• Production Welding
• Military
• Teaching
• Maintenance
• Robotics
• Ironworker/ Skilled
Trades
• Auto Technician
• Artist
• Metal Sculpting
• Owning Your Own
Business
Job opportunities in welding are changing …
Welding can be valuable as a job skill or as a full-time job
For more information on welding careers, please see the e-
learning introduction

12
How Much Money
Can You Make?
• Recent statistics show
that some welding jobs
pay $25.00 per hour
- If you worked five days a
week for one year, how
much money would you
make?
• 83% of people with
welding jobs were
offered medical benefits
- Higher than any other work
sector except government
For more information on welding statistics,
please log on to www.bls.gov

14
Application Activity
• Let’s explore some career
possibilities in welding
• Please log on to a computer
• Working with a team member,
research the websites to the right
and explore information about
welding careers
• In 60 minutes, be prepared to
answer the following questions:
– What careers in welding interest you
the most?
– How can welding be high tech?
– How much money can be made
annually in this chosen career field?
– Where can you get a job in welding
and what are the basic requirements?
– What are some job advancement
opportunities available in the welding
industry?
• America's Job Bank
(http://www.ajb.dni.us)
• Classifieds Employment
(http://www.classifieds2000.com)
• Yahoo! Careers
(http://careers.yahoo.com/)
• MONSTER.COM
(http://www.monster.com)
(http://nccer.monster.com)
• CareerBuilder
(http://www.careerbuilder.com)

16
• Welding can be safe when sufficient measures are
taken to protect yourself and others from potential
hazards
• Students should read and understand the following
before welding:
– Warning Labels
– Material Safety Data Sheets (MSDS)
• Students should also be familiar with the following
information
– ‘Safety in Welding, Cutting, and Allied Processes’ (ANSI Z49.1)
– Lincoln Electric’s ‘Arc Welding Safety’ (E205)
Arc Welding Safety

17
Warning Labels
• Understand and
follow all warning
labels found:
– On welding equipment
– With all consumable
packaging
– Within instruction
manuals

18
Material Safety Data Sheets
• Material Safety Data
Sheets (MSDS) are:
– Required by law and
OSHA
– Created by the
manufacturer of a product
per OSHA guidelines
– Designed to inform users
– Shipped with every box of
Lincoln Electric
consumable product
– Available free online at:
www.lincolnelectric.com/product
s/msds/
front

19
MSDS - Continued
• MSDS outlines a
product’s:
 Identity and
composition
 Potential hazards
 Safe use
 Handling information
 Manufacturer
contact information
back

20
ANSI Z49.1
• ANSI Z49.1: Safety in Welding, Cutting, and Allied
Processes
– A safety document published by the American Welding Society that
covers safe practices in the welding environment
– To get your free copy, go to:
 www.aws.org/technical/facts/Z49.1-2005-all.pdf
• E205: Arc Welding Safety
– A safety document summarizing many of the hazards and safe
practices for welding
– Download and print your own copy at:
 http://content.lincolnelectric.com/pdfs/products/literature/e205.pdf
– Free copies available from Lincoln Electric at:
 www.lincolnelectric.com/products/litrequest
• Access the E-learning Site @ www.agedlearning.com

21
Arc Welding Safety
• Protect yourself and
others from potential
hazards including:
– Fumes and Gases
– Electric Shock
– Arc Rays
– Fire and Explosion
Hazards
– Noise
– Hot objects

22
Fumes and Gases
• Fumes and gases can be
hazardous to your health
• Keep your head out of the
fumes
• Use enough ventilation,
exhaust at the arc, or both,
to keep fumes and gases
from your breathing zone
and the general area
• See product labeling and
MSDS for ventilation and
respirator requirements

23
Electric Shock
• Electric shock can kill
• Do not touch live electrical
parts
– Primary Voltage –230, 460
volt input power
– Secondary Voltage – 6 to
100 volts for welding
• Insulate yourself from
work and ground
• Follow all warnings on
welding equipment
Do not make repairsDo not make repairs
yourself, alert youryourself, alert your
instructor immediately!instructor immediately!

24
Arc Rays
• Arc rays can injure eyes and
burn skin
• The welding arc is brighter
than the sun
• Precaution must be taken to
protect your eyes and skin
from UV radiation
• Wear correct eye and body
protection

25
Fire and Explosion Hazards
• Welding sparks can cause
fires and explosions
• Sparks and spatter from the
welding arc can spray up to
35 feet from your work
• Flammable materials should
be removed from the welding
area or shielded from sparks
and spatter
• Have a fire extinguisher ready
• Inspect area for fires 30
minutes after welding

26
Noise
• Loud noises can damage your hearing
• Keep loud noises at a safe level by using proper
hearing protection such as:
– Ear plugs
– Ear muffs

27
Protective Clothing
Welders must wear protective
clothing for
– Protection from sparks, spatter and UV
radiation
– Insulation from electric shock
• Protective clothing includes …
– Fire-proof clothing without rolled sleeves,
cuffs or frays
– Work boots
– Welding gloves, jackets, bibs, and fire-
proof pants
– Welding cap, helmet and safety glasses
– Ear protection – ear plugs and muffs

29
Application Activity
• TIME TO PRACTICE
– Go out to the lab
– Demonstrate the use
of proper safety
precautions such as:
 Reading warnings
 Using proper protective
clothing
 Equipment inspection
 Keeping your head out
of the fume
 Proper ventilation

30
Basic Electricity and
Welding

31
The Arc Welding Circuit
• The electricity flows
from the power
source, through the
electrode and across
the arc, through the
base material to the
work lead and back
to the power source

32
Basic Electricity
• Voltage – The electrical
potential or pressure that
causes current to flow
– Measured in Volts
• Current – The movement
of charged particles in a
specific direction
– Measured in Amps
• Polarity
– DC- (Direct Current
Electrode Negative)
– DC+ (Direct Current
Electrode Positive)
– AC (Alternating Current)
DC+
DC -
AC

34
Math Terms in Welding
• Believe it or not, a lot of math is used in welding
IPM Travel Speed = Inches per
Minute Travel Speed
The speed the electrode moves
along the base material
IPM Wire Feed Speed= Inches
per Minute Wire Feed Speed
The speed at which the wire is
fed during wire welding
Lbs/hr = Pounds per Hour Electrode deposition rate
CFH= Cubic Feet per Hour Shielding gas flow rate (wire
welding)
PSI= Pounds per Square Inch Tensile strength of a material and
the pressure in gas cylinders
L = Leg Fillet size measurement
% = percent Shielding gas mixture
composition

36
Can All Metals Be Welded?
• Most metals can be welded, but not all
• The three most common weldable metals
include:
– Mild Steel - inexpensive and strong
– Stainless Steel – does not rust
– Aluminum – does not rust and is light weight
Mild steel Stainless Steel Aluminum

37
Gauge
• Material thickness is sometimes measured by
gauge from 36 (.004 in) to 3 (.2391 in)
– For example, steel gauge and measurement in inches:
PLEASE NOTE: As the gauge number gets smaller … the material thickness gets larger.
16 gauge = .051” 14 gauge = .064” 12 gauge = .081” 10 gauge = .102”

39
Types of Joints
• There are 5 types of
joints …

41
Parts of a Weld
Joint and WeldJoint and Weld
Heat Affected ZoneHeat Affected Zone

42
Fillet and Groove Welds
• Groove and fillet welds can be made on many
types of joints

43
Fillet Weld Inspection
• Fillet welds should:
– Have a flat to slightly convex face
– Be uniform in appearance
– Have equal leg size
– Have good wash-in into base materials
• This is an example of a good fillet weld:

45
What are Welding Symbols?
• Welding symbols give
the welder specific
instructions about the
weld including:
– Placement
– Size
– Length
– Process
– Any other special
notes
• Welding symbols are
– Universally used
– Governed by the AWS
– Found on engineering
drawings
“How to Read Shop Drawings”
available at www.jflf.org

46
Welding Symbols
• Welding symbols contain information about the
weld to be made
– S – leg dimension of the weld
– Triangle – the weld is to be made on the arrow side of this joint
– Tail – any additional information required (i.e. position the weld
is to be made)
– Arrow - the joint the welding symbol applies to

48
What are Welding Positions?
• There are various positions that a weld can be made in:

50
What are the
Responsibilities of a Welder?
• Welders have many areas of
important responsibilities
• These relate to:
– Arc Welding Safety
– Knowledge – Content
– Attitude – Reactions
– Skills – Performance
– Work Habits – Daily Functions
Always keep safety in
mind when welding

51
Arc Welding Safety
• A welder MUST always follow safe work
practices:
– Students should read and understand the following before
welding:
 Warning Labels
 Material Safety Data Sheets (MSDS)
– Students should also be familiar with the following information
 ‘Safety in Welding, Cutting, and Allied Processes’ (ANSI Z49.1)
 Lincoln Electric’s ‘Arc Welding Safety’ (E205)

52
Knowledge - Content
• Welding can teach
you about….
– Science when applying
metallurgy, chemistry,
electricity, etc.
– Math when calculating
angles, joint design, and
weld size
– English when
communicating and
interpreting drawings,
codes, and procedures
– Technical areas when
performing the actual
welding applications
How much science and
math went into the
development of this bike?

53
Attitude
• The best welders
demonstrate a can-do
attitude when performing
welding processes
• This means being able to…
– Work as a team member
– Communicate ideas to others
– Listen to opinions of others
– Promote a positive attitude
– Provide solutions to problems
– Take pride in workmanship
These welders work together
to inspect a weld.

54
Skills/Performance
• A welder must
demonstrate technical
skills when performing
welding processes
• A welder must know how
to:
– Use hand tools and materials,
to operate equipment in a safe,
accurate, and consistent
manner
– Acquire and evaluate
information needed for
problem solving
– Complete quality work
– Maintain equipment
There is no room for poor
workmanship in NASCAR

55
Work Habits/Daily Functions
• A welder must practice good
working habits when
performing welding
processes
• This means being able to …
– Follow detailed verbal and
written instructions
– Maintain workspace,
equipment, and tool
cleanliness
– Correctly fill out, maintain and
submit time cards, work
assignment cards, and other
records as required
– Follow safe working practices
Agriculture teachers brush
up on their welding skills at
Lincoln Electric’s Welding
Educator’s Workshop

57
Welding Certification
• What is a welding certification?
– Welding certifications are used to test a welder’s knowledge and
welding skill
– Certifications are available for many different processes, materials, and
positions.
• Who certifies welders?
– Certification programs are offered by many different types of
organizations:
 Companies
 Skilled Trades
 Military
 Ship Builders
 Pipelines
 The American Welding Society

58
Welding Certification
• How can you become certified?
– Certification testing is available at testing facilities all over the
United States
– The AWS offers many certifications including: welders, welding
inspectors, and welding educators
• What is the value of a welding certification?
– A welding certification proves that you have passed a test and are
qualified for the job
– As an AWS certified welder your name is kept in a national
database which is used to notify you of jobs open in your area
– It is a source of accomplishment and pride

59
English, Math, and
Science Connection

60
English, Math, and
Science Connection
• Many of the same concepts you learn in other
classes are practiced in welding. In what other
classes might you study the following terms?
 75/25 – gas mixture
 Volts
 Amps
 Degree/hr – cooling rate
 In/min
 Angles/degrees
 Metallurgy
 Fillet size
 Current
 Tension
 Compression
 Tensile strength
 Yield
 Blueprints
 Depth/width ratio
 Preheat temperature
 Cubic feet per hour

61
National Academic Standards
Crosswalk
• The unit just completed has covered parts of
academic content listed in the National
Academic Standards as follows:
– NM-PROB.CONN.PK-12.3: Recognizes and applies
mathematics in contexts outside of mathematics.
– NLA-STANDARD 1: Uses the general skills and strategies of
the writing process.
– NLA-STANDARD 7: Uses reading skills and strategies to
understand and interpret a variety of informational texts.
– NS-PHYSICAL SCIENCE: (Experiences) interactions of
energy and matter.

Arc weldingbasics

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