Introduction to Welding Tech Connect Welding Tech Connect Welding.

Introduction to Welding

Introduction to Welding

Tech ConnectWeldingTech ConnectWelding

The Welding IndustryThe Welding Industry

Welding has been around since ancient times.Welding has been around since ancient times.

The purpose of welding is to join metal parts or The purpose of welding is to join metal parts or pieces together.pieces together.

Some of the industries that employ welders Some of the industries that employ welders include automobile, heavy equipment include automobile, heavy equipment manufacturers, power companies, oil and gas, manufacturers, power companies, oil and gas, aerospace, and manufacturing.aerospace, and manufacturing.

Welding ProcessesWelding Processes

Oxyfuel Gas Welding (OFW)Oxyfuel Gas Welding (OFW)

•Also known as “oxyacetylene welding”Also known as “oxyacetylene welding”

•Uses an oxyfuel gas flameUses an oxyfuel gas flame

•Can be applied with or without pressureCan be applied with or without pressure

•Can be applied with or without the use of Can be applied with or without the use of filler materialsfiller materials

Shielded Metal Arc Welding (SMAW)Shielded Metal Arc Welding (SMAW)

•Also known as “stick welding”Also known as “stick welding”

•Uses an arc between a covered electrode Uses an arc between a covered electrode and a workpieceand a workpiece

•Shielding is obtained from decomposition of Shielding is obtained from decomposition of the electrode coverthe electrode cover

•Pressure is not usedPressure is not used

Welding Processes (continued)Welding Processes (continued)

•Filler metal is obtained from the electrodeFiller metal is obtained from the electrode

Shielded Metal Arc Welding (SMAW) Shielded Metal Arc Welding (SMAW) (continued)(continued)

•Is popular because it can be used in the Is popular because it can be used in the field without complicated equipment and field without complicated equipment and gasesgases•Mainly used for repair work and occasional Mainly used for repair work and occasional weldingwelding


Gas Tungsten Arc Welding (GTAW)Gas Tungsten Arc Welding (GTAW)

•Also known as Tungsten Inert Gas (TIG) Also known as Tungsten Inert Gas (TIG) welding, Heliarc, or Heliweldwelding, Heliarc, or Heliweld•Uses an arc between a nonconsumable Uses an arc between a nonconsumable tungsten electrode and a workpiecetungsten electrode and a workpiece

•Shielding is obtained from a gasShielding is obtained from a gas

•Can be applied with or without a filler metalCan be applied with or without a filler metal


Gas Tungsten Arc Welding (GTAW) Gas Tungsten Arc Welding (GTAW) (continued)(continued)


•Used in the food, aerospace and nuclear Used in the food, aerospace and nuclear industriesindustries

•Commonly used to weld aluminum, Commonly used to weld aluminum, magnesium, copper, and thin sections of magnesium, copper, and thin sections of stainless steelstainless steel

Gas Metal Arc Welding (GMAW)Gas Metal Arc Welding (GMAW)

•Also known as Metal Inert Gas (MIG) Also known as Metal Inert Gas (MIG) welding, or Metal Active Gas (MAG) weldingwelding, or Metal Active Gas (MAG) welding•Uses an arc between a continuous filler Uses an arc between a continuous filler metal and a workpiecemetal and a workpiece

•Shielding is obtained entirely from an Shielding is obtained entirely from an externally supplied gasexternally supplied gas•Used in the automobile industry, high-Used in the automobile industry, high-production manufacturing and constructionproduction manufacturing and construction


Flux-Cored Arc Welding (FCAW)Flux-Cored Arc Welding (FCAW)

•Uses an arc between a continuous filler Uses an arc between a continuous filler metal electrode and a workpiecemetal electrode and a workpiece•Shielding is provided by a flux contained Shielding is provided by a flux contained within the electrodewithin the electrode

•Additional shielding may be obtained from Additional shielding may be obtained from an externally supplied gas or gas mixturean externally supplied gas or gas mixture•Commonly used in construction because it Commonly used in construction because it is a fast welding process and is easily is a fast welding process and is easily portableportable


Submerged Arc Welding (SAW)Submerged Arc Welding (SAW)

•Uses an arc between a bare metal electrode Uses an arc between a bare metal electrode and a workpieceand a workpiece•A layer of granulated mineral material A layer of granulated mineral material covers the tip of the electrode, the arc, and covers the tip of the electrode, the arc, and the workpiece in order to protect the work the workpiece in order to protect the work from contaminations in the airfrom contaminations in the air•Pressure is not usedPressure is not used

•Filler metal is obtained from the electrode or Filler metal is obtained from the electrode or from a supplemental sourcefrom a supplemental source


•Produces no arc, sparks, splatter or smokeProduces no arc, sparks, splatter or smoke

Submerged Arc Welding (SAW) Submerged Arc Welding (SAW) (continued)(continued)


•Uses a constricted arc between a Uses a constricted arc between a nonconsumable electrode and a workpiece nonconsumable electrode and a workpiece (transferred arc) or the electrode and a (transferred arc) or the electrode and a constricting nozzle (nontransferred arc).constricting nozzle (nontransferred arc).

•Shielding is obtained from the hot, ionized Shielding is obtained from the hot, ionized gas issuing from the torchgas issuing from the torch•Shielding gas can be an inert gas or a Shielding gas can be an inert gas or a mixture of gassesmixture of gasses•Can be applied with or without the use of Can be applied with or without the use of filler materialfiller material

SolderingSoldering

•A method of bonding two metal surfaces A method of bonding two metal surfaces without melting the main workpiecewithout melting the main workpiece•Produces coalescence of material by using Produces coalescence of material by using a filler metal, which has a melting point a filler metal, which has a melting point below 842°F (450°C)below 842°F (450°C)

•Primarily used on electrical, electronic, and Primarily used on electrical, electronic, and other small equipmentother small equipment

Soldering, Brazing & Cutting Processes

Soldering, Brazing & Cutting Processes

BrazingBrazing

•Like soldering, is also a method of bonding Like soldering, is also a method of bonding two metal surfaces without melting the main two metal surfaces without melting the main workpieceworkpiece•Used with metals that have higher melting Used with metals that have higher melting points than used with soldering and points than used with soldering and produces a stronger bondproduces a stronger bond•Produces coalescence of materials by using Produces coalescence of materials by using a filler metal, which is heated to above 842a filler metal, which is heated to above 842ºF ºF (450(450ºC) but below the melting point of the ºC) but below the melting point of the base metalbase metal

Soldering, Brazing & Cutting Processes (continued)


Cutting processesCutting processes

•Oxyfuel Gas Cutting (OFC) – cuts metal by Oxyfuel Gas Cutting (OFC) – cuts metal by applying heat to cause a chemical reaction applying heat to cause a chemical reaction between oxygen and the base metalbetween oxygen and the base metal

•Carbon Arc Cutting (CAC) – cuts or Carbon Arc Cutting (CAC) – cuts or removes metal by using the heat of the arc removes metal by using the heat of the arc between the electrode and the workpiece to between the electrode and the workpiece to cause meltingcause melting



•Machine ManufacturersMachine Manufacturers

•TransportationTransportation

•Repair ServicesRepair Services

Types of Industries That Hire Welders

Types of Industries That Hire Welders

•Mining and DrillingMining and Drilling

•Fabricated MetalsFabricated Metals

•Metal IndustriesMetal Industries

•Electrical Equipment ManufacturersElectrical Equipment Manufacturers

•Depending on the job requirements, work can Depending on the job requirements, work can either be accomplished indoors or outdoorseither be accomplished indoors or outdoors

•Employees normally work in 8-hour shifts with a Employees normally work in 8-hour shifts with a 40-hour work week40-hour work week

•Employees usually work alone with very little Employees usually work alone with very little social contactsocial contact

Working Conditions in the Field of Welding

Working Conditions in the Field of Welding

•Safety equipment is required, such as safety Safety equipment is required, such as safety shoes, goggles, and hoodsshoes, goggles, and hoods

•Exposure to hazards is possible, such as Exposure to hazards is possible, such as contaminants, hazardous equipment, extremely contaminants, hazardous equipment, extremely bright light, or loud noise levelsbright light, or loud noise levels

•Physical demands include using hands, standing Physical demands include using hands, standing for long periods of time, repetitive movements, for long periods of time, repetitive movements, bending, kneeling, stooping, crouching, crawling, bending, kneeling, stooping, crouching, crawling, climbing, or liftingclimbing, or lifting

Working Conditions in the Field of Welding (continued)

Working Conditions in the Field of Welding (continued)

•Jobs may require working with different materials Jobs may require working with different materials such as plastic, titanium, aluminum, or steelsuch as plastic, titanium, aluminum, or steel

Physical traitsPhysical traits

•Good physical condition that enables bending, Good physical condition that enables bending, stooping, and holding uncomfortable positions for a stooping, and holding uncomfortable positions for a long period of timelong period of time

•Good eyesightGood eyesight

•Good hand-eye coordinationGood hand-eye coordination

Requirements for Becoming a Welder

Requirements for Becoming a Welder

•Working well with your handsWorking well with your hands

EducationEducation

•High school diploma or GEDHigh school diploma or GED

•Training through one or more of the following:Training through one or more of the following:

-Academic programs-Academic programs-On-the job training-On-the job training-Apprenticeship training-Apprenticeship training-Military training-Military training

Requirements for Becoming a Welder (continued)


Personal traits and abilitiesPersonal traits and abilities



•Maintain a detail-oriented outlookMaintain a detail-oriented outlook

•Understand written informationUnderstand written information

•Visualize objects from drawingsVisualize objects from drawings

•Ability to add, subtract, multiply, divide quickly and Ability to add, subtract, multiply, divide quickly and correctlycorrectly•Organize work without direct supervisionOrganize work without direct supervision

•Acquire needed information when necessaryAcquire needed information when necessary

•Perform repetitive activitiesPerform repetitive activities

Personal traits and abilities Personal traits and abilities (continued)(continued)



•Concentrate while performing a task without being Concentrate while performing a task without being distracteddistracted•Follow procedures carefullyFollow procedures carefully

•Notice when something is wrong or likely to go Notice when something is wrong or likely to go wrongwrong•Judge the value of your own workJudge the value of your own work

Learned SkillsLearned Skills



•Use and handle different tools and equipmentUse and handle different tools and equipment

•Determine correct tools to use for each jobDetermine correct tools to use for each job

•Read and interpret blueprintsRead and interpret blueprints

•Understand arc, gas, and resistance welding theoryUnderstand arc, gas, and resistance welding theory

•Follow specifications to lay out, cut and form metalsFollow specifications to lay out, cut and form metals

•Use the different types of welding processesUse the different types of welding processes

•Correctly operate machineryCorrectly operate machinery

Learned Skills Learned Skills (continued)(continued)



•Install and repair machinery and equipmentInstall and repair machinery and equipment

•Perform special processes such as welding studs Perform special processes such as welding studs and brazingand brazing

•Ensure quality products before, during and after Ensure quality products before, during and after weldingwelding

The Work Process of Welding Materials

The Work Process of Welding Materials

•Read the given blueprint or detailed work order to Read the given blueprint or detailed work order to plan what needs to be doneplan what needs to be done

•Determine the correct tools to useDetermine the correct tools to use

•Put on personal protective clothing and equipmentPut on personal protective clothing and equipment

•Properly set up the necessary equipmentProperly set up the necessary equipment

•Position and secure the workpiece using a hoist, Position and secure the workpiece using a hoist, hand tools, or other equipmenthand tools, or other equipment•Clean the surface of the metals using appropriate Clean the surface of the metals using appropriate tools or chemicalstools or chemicals

The Work Process of Welding Materials (continued)

The Work Process of Welding Materials (continued)

•Start the equipment and ignite the torchStart the equipment and ignite the torch•Adjust valves and regulate flow of gas and airAdjust valves and regulate flow of gas and air

•Weld the metal parts togetherWeld the metal parts together

•When job is completed, use hand or power tools to When job is completed, use hand or power tools to chip or grind off excess weld or solderchip or grind off excess weld or solder

•Examine the welded materials to verify the final Examine the welded materials to verify the final product meets outlined requirementsproduct meets outlined requirements

Purpose of standardsPurpose of standards

•Describe the technical requirements for a material, Describe the technical requirements for a material, process, product, system, or serviceprocess, product, system, or service

•Indicate the procedures, methods, equipment, and Indicate the procedures, methods, equipment, and tests that should be used to verify the requirements tests that should be used to verify the requirements have been methave been met

Welding StandardsWelding Standards

Types of standardsTypes of standards

•Codes – Indicate mandatory materials and actions Codes – Indicate mandatory materials and actions when completing a specific processwhen completing a specific process

•Specifications – Indicate mandatory materials and Specifications – Indicate mandatory materials and actions when working with a specific productactions when working with a specific product

Welding Standards (continued)Welding Standards (continued)

Important standardsImportant standards

•Standard for Welding Procedure and Performance Standard for Welding Procedure and Performance QualificationQualification

•Standard Symbols for Welding, Brazing, and Standard Symbols for Welding, Brazing, and Nondestructive ExaminationNondestructive Examination

Welding Standards (continued)Welding Standards (continued)

•Standard Welding Terms and DefinitionsStandard Welding Terms and Definitions

Free Enterprise in the Welding Industry

Free Enterprise in the Welding Industry

•In 2004, there were 429,000 welding, soldering, and In 2004, there were 429,000 welding, soldering, and brazing workers in the United Statesbrazing workers in the United States

•Approximately 7% of workers are self-employedApproximately 7% of workers are self-employed

•By 2010, there will be a shortage of approximately By 2010, there will be a shortage of approximately 250,000 qualified welders250,000 qualified welders

•The need for less skilled welders will decrease as The need for less skilled welders will decrease as more processes become automated, and the need more processes become automated, and the need for highly skilled welders with formal training will for highly skilled welders with formal training will increaseincrease

Free Enterprise in the Welding Industry (continued)


•Manufacturing industries currently employ the Manufacturing industries currently employ the largest number of workers, however this market will largest number of workers, however this market will decline as jobs move overseasdecline as jobs move overseas

•Growth over the next 10 years will occur in the Growth over the next 10 years will occur in the construction industryconstruction industry

•Welding, soldering, and brazing jobs as a whole are Welding, soldering, and brazing jobs as a whole are expected to grow slower than average through 2014expected to grow slower than average through 2014



•Most welders work 40 hours a week but overtime is Most welders work 40 hours a week but overtime is common, with some workers putting in up to 70 common, with some workers putting in up to 70 hours a week. Shift workers can work 12 hour shifts hours a week. Shift workers can work 12 hour shifts in factories that operate 24 hours a day.in factories that operate 24 hours a day.

•Hourly pay rates usually range from $11.90 to Hourly pay rates usually range from $11.90 to $18.05$18.05

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