Arc Welding Basics

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

Introduction
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 . its 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

10
Careers in Welding




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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
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Application Activity




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Application Activity
Lets 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)



15
Welding Safety




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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 Electrics 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
products:
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 repairs
yourself, alert your
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
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Application Activity




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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


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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
33
Math Terms
and Welding



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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
35
Metals



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
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Types of Joints



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Types of Joints
There are 5 types of
joints
40
Parts of a Weld




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Parts of a Weld
Joint and Weld
Heat 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:
44
Welding Symbols



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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

47
Welding Positions



48
What are Welding Positions?
There are various positions that a weld can be made in:
49
Welder
Responsibilities



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 Electrics 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 Electrics Welding
Educators Workshop
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Welding Certification



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Welding Certification
What is a welding certification?
Welding certifications are used to test a welders 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
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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.