Arc Welding Basics

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

2
 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

3
Introduction
 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 Root Pass or Final weld after

Welded Stringer Bead several beads are
made
5
 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

6
 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

7
 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

8
 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

9
Careers in Welding

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 Careers in Welding

Job opportunities in welding are changing

Welding can be valuable as a job skill or as a full-time job

Engineering Robotics
Ironworker/ Skilled Trades
Racing
Auto Technician
Industrial Sales Artist
Farm Repair and Fabrication Metal Sculpting
Owning Your Own Business
Production Welding
Military
Teaching
Maintenance
For more information on welding careers, please see the e-
learning introduction

11
 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

12
Application Activity

13
 Application Activity
Lets explore some career America's Job Bank
possibilities in welding (http://www.ajb.dni.us)
Please log on to a computer Classifieds Employment
(http://www.classifieds2000.com)
Working with a team member,
research the websites to the right
Yahoo! Careers
and explore information about (http://careers.yahoo.com/)
welding careers MONSTER.COM
In 60 minutes, be prepared to (http://www.monster.com)
answer the following questions: (http://nccer.monster.com)
What careers in welding interest you CareerBuilder
the most? (http://www.careerbuilder.com)
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?

14
Welding Safety

15
 Arc Welding Safety

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)

16
 Warning Labels

Understand and
follow all warning
labels found:
On welding equipment
With all consumable
packaging
Within instruction
manuals

17
 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
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 MSDS - Continued

MSDS outlines a
products:
Identity and
composition
Potential hazards
Safe use
Handling information
Manufacturer
contact information

back
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 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

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 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

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 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

22
 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
Do not make repairs
Follow all warnings on yourself, alert your
welding equipment instructor immediately!

23
 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

24
 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

25
 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

26
 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

27
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

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 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

31
 Basic Electricity
DC -
Voltage The electrical
potential or pressure that
causes current to flow
Measured in Volts
DC+
Current The movement
of charged particles in a
specific direction
Measured in Amps AC
Polarity
DC- (Direct Current
Electrode Negative)
DC+ (Direct Current
Electrode Positive)
AC (Alternating Current)

32
Math Terms
and Welding

33

Believe it or not, a lot of math is used in welding
IPM Travel Speed = Inches per
Minute Travel Speed
IPM Wire Feed Speed= Inches
per Minute Wire Feed Speed
Lbs/hr = Pounds per Hour
CFH= Cubic Feet per Hour
PSI= Pounds per Square Inch
L = Leg
% = percent
Math Terms in Welding
The speed the electrode moves
along the base material
The speed at which the wire is
fed during wire welding
Electrode deposition rate
Shielding gas flow rate (wire
welding)
Tensile strength of a material and
the pressure in gas cylinders
Fillet size measurement
Shielding gas mixture
composition
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Metals

35
 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

36
 Gauge

Material thickness is sometimes measured by

gauge from 36 (.004 in) to 3 (.2391 in)
For example, steel gauge and measurement in inches:

16 gauge = .051 14 gauge = .064 12 gauge = .081 10 gauge = .102

PLEASE NOTE: As the gauge number gets smaller the material thickness gets larger.

37
Types of Joints

38
 Types of Joints

There are 5 types of

joints

39
Parts of a Weld

40
 Parts of a Weld

Heat Affected Zone

Joint and Weld

41
 Fillet and Groove Welds

Groove and fillet welds can be made on many

types of joints

42
 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:

43
Welding Symbols

44
 What are Welding Symbols?

Welding symbols give Welding symbols are

the welder specific Universally used
instructions about the Governed by the AWS
weld including: Found on engineering
Placement drawings
Size
Length
Process
Any other special
notes
How to Read Shop Drawings
available at www.jflf.org
45
 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

46
Welding Positions

47
 What are Welding Positions?

There are various positions that a weld can be made in:

48
 Welder
Responsibilities

49
 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

50
 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)

51
 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 How much science and
welding applications math went into the
development of this bike?

52
 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
These welders work together
Provide solutions to problems to inspect a weld.
Take pride in workmanship

53
 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

54
 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 Agriculture teachers brush
submit time cards, work up on their welding skills at
assignment cards, and other Lincoln Electrics Welding
records as required Educators Workshop
Follow safe working practices

55
Welding Certification

56
 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

57
 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

58
 English, Math, and
Science Connection

59
 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 Current
Volts Tension
Amps
Compression
Tensile strength
Degree/hr cooling rate
Yield
In/min
Blueprints
Angles/degrees Depth/width ratio
Metallurgy Preheat temperature
Fillet size Cubic feet per hour

60
 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.

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