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2 ARC WELDING BASICS What is Arc Welding? Why is Welding Important? Why Learn to Weld?

PowerPoint Presentation:

3 ARC WELDING BASICS What is Arc Welding? Why is Welding Important? Why Learn to Weld?

What is Arc Welding?:

4 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

Why is Welding Important?:

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

Why Learn to Weld?:

6 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

Basic Steps of Arc Welding:

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

Welding Safety:

8 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

Warning Labels:

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

Arc Welding Safety:

10 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

Fumes and Gases:

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

Electric Shock:

12 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 !

Arc Rays:

13 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

Fire and Explosion Hazards:

14 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


15 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

Protective Clothing:

16 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


Remember…! Reading warnings Using proper protective clothing Equipment inspection Keeping your head out of the fume Proper ventilation 17

Welder Responsibilities:

Welder Responsibilities 18

What are the Responsibilities of a Welder?:

19 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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20 Basic Electricity and Welding

The Arc Welding Circuit :

21 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

Basic Electricity:

22 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


METALS Can All Metals Be Welded? 23

Can All Metals Be Welded? :

24 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


25 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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27 There are 5 types of joints … TYPES OF JOINT

Fillet and Groove Welds:

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

Parts of a Weld:

29 Parts of a Weld Joint and Weld Heat Affected Zone

Fillet Weld Inspection:

30 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:

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31 Welding Symbols

What are Welding Symbols?:

32 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

Welding Symbols:

33 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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34 Welding Positions There are various positions that a weld can be made in:


35 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.


36 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

Work Habits/Daily Functions:

37 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

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