What is Welding and Types of Welding?

● Necessary Clothing: Safety glasses, jacket, long pants, leather shoes, gloves, cotton
clothes.

● OSHA: Occupational Safety and Health Administration.

● Welding Process: A concentrated heat source melts the material in the weld area, the
molten area then solidifies to join the pieces together. Sometimes a filler material is
added to the molten pool to strengthen the weld.

● Physics of Welding: In fusion welding, a source of high-density heat energy raises the
temperature of the surfaces enough to cause localized melting; if the heat density( power
+ surface area) is too low, the heat is conducted away as fast as it is added and melting
does not occur.

● Current types of welding for manufacturing: Fusion welding, oxyfuel welding

Gas Metal Arc Welding (MIG)

● DCEP: One negative wire and one positive.

Electrode Extension

● Adjustments in the distance cause a change in the wire

Power Settings

● Wire speed knob, a faster wire speed will require more amps to keep it from melting.
● Voltage control knob, the thicker the metal the more voltage required.

Weave Patterns

● Welders use a variety of weave patterns. Some are better for certain types of welding,
certain metals, and certain positions.

Gun Angle

● This is the angle of the gun in relation to the workpiece.

 ● The arc force can be used to counteract the gravitational force on the molten weld pool.

Travel Speed

● The arc needs to be kept right at the front of the weld pool.
● Too fast and you can overrun the ability of the arc to melt the base metal which results in
poor fusion.
● Too slow and the weld pool gets excessively large.

Safety Questions

1. Following the rules, regulations, and the procedures for the welding process.
2. The welder.
3. 1st Degree: Surface of skin, reddish, tender, and painful (no broken skin).
2nd Degree: Surface of skin severely damaged, blisters, and possible break of skin.
3rd Degree: Surface of skin and possible tissue below skin appear white and charred.
4. 1st Degree: Put cold water on burn area
2nd Degree: Burn area under cold water.
3rd Degree: Don’t remove clothing, smother flames if any, call ambulance.
5. Ultraviolet, Infrared, visible.
6. Ultraviolet if welder is close to arc with higher current and quicker burn.
7. Painted in flat black colored or black paint if not weld curtains.
8. Flash burn.
9. Can injure the white of the eye or the retina.
10. Possible loss of eyesight and risk of infection.
11. 100% wool, 100% cotton. Dark colored and thick woven.
12. Shirt - long sleeved, pants - long enough to cover tops of boots and without cuffs, boots -
must have high tops, caps - should be thick.
13. They may catch fire or explode.
14. All leather gauntlet type gloves, leather jackets, aprons, leather pants and spats.
15. To avoid debris and light reflection and excessive exposure to arc light.
16. Causes of pain and loss of hearing, burns.
17. Ear muffs and ear plugs.
18. Proper respirator use, Maintenance schedules and respiratory selection, regular program
evaluation.
19. Demand respirators are atmosphere supplying respirators that admit breathing air to the face
piece only when a negative pressure is created inside the face piece by inhalation. Positive
pressure respirators are respirators in which the pressure inside the respiratory inlet covering
exceeds the ambient air pressure outside the respirator.
20. Paints, coating, or plating or metals.
21. Some contain lead based painting.
22. 10,000 cubic feet or more per welder or 16 fight or higher ceilings.
23. Good for the environment and generate revenue for the welding shop.
24. In small shops or shops with large number of welders and welding metals that give off
dangerous fumes.
25. Must be provided to anyone with the product or working in the area where the product is in
use.
26. Located away from halls, stairways, and exits and away from heat, radiators, furnaces, and
welding sparks. Stored separately by 20 feet or by a wall 5 feet high with at least ½ hour burning
rate.
27. Secured with chain or other device and with a valve protection clap.
28. It should be moved to a vacant lot or an open area, then pressure should be slowly released
after posting warning sign.
29. May draw acetone out of the cylinder which lowers the flame temperature and can damage
regulator or torch valve settings.
30. WHen performing welding outside of the shop.
31. 35 feet or more.
32. When someone sounds the fire alarm and uses the fire extinguishers.
33. Type A fire extinguisher - combustible, Type B fire extinguisher - combustible liquids, Type
C fire extinguisher - combustible electricals, Type D fire extinguisher - combustible metals.
34. Will aid in detecting potential problems such as leaking coolant, loose wires, poor grounds,
frayed insulation, or split hoses.
35. To prevent tripping and injury.
36. Write the word “Hot”.
37. May result in chips flying off and causing injury.
38. Accidental contact with bare or poorly insulated conductors.
39. Metal enclosure, wetness, restricted entry, heavier than air gas, welder inside or on
workpiece.
40. Overheat and break down the insulation rapidly.
41. Prevent electrocution.
42. 12.
43. Ground fault circuit interpreter - fast acting circuit breakers that shut off the power to an
electrical circuit when detected a small imbalance in circuits electrical flow.
44. Connect cord to tool into extension cord first, unplug extension cord receptacle first,
extension cords should not come in contact with sharp objects and must be positioned
appropriately, check for loose or exposed wire and unusual heating, use a knot to prevent
accidental separation.
45. Know the tool and ground when needed, do not expose to water, do not force a cutting tool to
cut faster, use the right tool for the right job, wear eye and face protection, secure your work with
clamps, disconnect from power source when not in use, check to see keys and wrench are
removed, avoid accidental starting, be sure accessories and bits are attached securely.
46. You can get an electric shock or electrocution.
47. Pedestal grinder and portable grinder.
48. 1/16 inch.
49. Shear, punches, cut-off machines, and band saws. Advantages are thermal cutting include
little or no post-cutting cleanup, wide variety of metals can be cut, and the metal is not heated.
50. Weight of the object should be distributed evenly between both hands, and your legs should
be used to lift, not your back.
51. Look for loose or damaged steps, rungs, rails, braces, and safety feet. Check hardware is
tight. If wooden ladder, check for rot.
52. Tie ladder securely in place, Do not exceed the manufacturer’s recommended weight limit,
climb and descend the ladder cautiously, Never use ladders around live electrical wires, wear
well-fitted shoes or boots.

Shielding Gas

Helium Alloys, CO2: Creates a stronger weld, better penetration into the metal
Argon
Argon-Helium
Undercut: cut base metal too much.