A Introduction

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

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Arc Welding Basics
 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
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 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

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 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

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 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

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 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
• Let’s 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?

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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 Electric’s ‘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/products
/msds/
front
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 MSDS - Continued

• MSDS outlines a
product’s:
 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

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 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

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 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

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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

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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

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 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)

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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 (.0068″) to 3 (.2391″)
– For example, steel gauge and measurement in inches:

16 gauge = .062″ 14 gauge = .078″ 12 gauge = .105″ 10 gauge = .135″

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

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Types of Joints

38
 Types of Joints

• There are 5 types of

joints …

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Parts of a Weld

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 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

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 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
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 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

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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

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 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)

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

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 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 Electric’s Welding
records as required Educator’s Workshop
– Follow safe working practices

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Welding Certification

56
 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

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

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 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

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 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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