ArcWeldingBasics.ppt

Arc Welding BasicsArc Welding Basics

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Unit Topics 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

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ObjectivesObjectives

• 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 Introduction

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What is Arc Welding?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

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Why is Welding Important?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?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 WeldingBasic 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 SocietyThe 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

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Careers in WeldingCareers in Welding

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Careers in WeldingCareers 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

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How Much Money Can You Make?

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 ActivityApplication Activity

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• 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)

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Welding SafetyWelding 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 Electric’s ‘Arc Welding Safety’ (E205)

Arc Welding SafetyArc Welding Safety

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Warning LabelsWarning Labels

• Understand and follow all warning labels found: – On welding equipment– With all consumable

packaging – Within instruction

manuals

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Material Safety Data SheetsMaterial 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 - ContinuedMSDS - Continued

• MSDS outlines a product’s:

Identity and composition

Potential hazards Safe use Handling information Manufacturer

contact information

back

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ANSI Z49.1ANSI 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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• 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 GasesFumes 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

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Electric ShockElectric 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 Do not make repairs yourself, alert your yourself, alert your

instructor immediately!instructor immediately!

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Arc RaysArc 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 HazardsFire 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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NoiseNoise

• Loud noises can damage your hearing• Keep loud noises at a safe level by using proper

hearing protection such as:– Ear plugs – Ear muffs

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Protective ClothingProtective 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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• 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

Basic Electricity and Welding

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The Arc Welding Circuit 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 ElectricityBasic 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

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Math Terms and Welding

Math Terms and Welding

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Math Terms in Welding 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

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Metals Metals

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Can All Metals Be Welded? 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

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GaugeGauge

• 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 JointsTypes of Joints

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Types of Joints Types of Joints

• There are 5 types of joints …

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Parts of a WeldParts of a Weld

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Parts of a WeldParts of a Weld

Joint and WeldJoint and WeldHeat Affected ZoneHeat Affected Zone

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Fillet and Groove WeldsFillet and Groove Welds

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

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Fillet Weld InspectionFillet 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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Welding SymbolsWelding Symbols

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What are Welding Symbols?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

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Welding SymbolsWelding 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 PositionsWelding Positions

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What are Welding Positions?What are Welding Positions?

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

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Welder Responsibilities

Welder Responsibilities

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What are the Responsibilities of a Welder?

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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• 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)

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Knowledge - ContentKnowledge - 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?

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AttitudeAttitude

• 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.

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Skills/PerformanceSkills/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

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Work Habits/Daily FunctionsWork 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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Welding CertificationWelding Certification

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• 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

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• 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


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• 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

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National Academic Standards Crosswalk

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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ArcWeldingBasics.ppt