WELDING 101 BUYING GUIDES CAREER UND

HOW TO WELD – AN ULTIMATE

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Last Updated On: June 30th, 2020

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In some ways, discovering the art of welding is a contradictory experience

Initially, it seems simple. 

A er all, most people know that welding is just the act of joining two piece

But you begin to read more about the subject and then it appears much m

There are so many types, applications, joints and machines, that the whol

And that’s before you actually get down to fixing that car fender (or whatev

This ultimate guide to welding will show you that this process is not as com
would lead you to believe.

Once you understand the process, and the di erent types, it’s actually quit

So, read on and discover everything you need to know about this process c
 Quick Navigation

What Exactly Is Welding 101? What Materials A

What Is the History of Welding? Covered Electr

Bronze and Iron Ages GMAW Solid W

Middle Ages SAW Flux

The 19th Century How Do You Che

The 20th Century Visual

Why Is Welding Important for Industrial Production? Non-Destructiv

What Is the Di erence Between Brazing, Soldering and Welding? Destructive Tes

Brazing What Equipmen

Soldering Welding Machi

What Are the Di erent Types of Welding? Regulators

Oxy-Fuel Welding Welding Consu

Shielded Metal Arc Welding (Stick Welding) Welding Torch

Gas Tungsten Arc Welding (TIG Welding) Safety Equipm

Gas Metal Arc Welding (MIG Welding) Welding Safety

Flux Cored Arc Welding (FCAW) Welding Safety

What Is the Science Behind Welding? Is Welding a Goo

Welding for Beginners: The Process What Are the P

The Arc What Are the C

The Melt How Do I Becom

The Filler High School

The Shield Become Traine

The Cool Obtain A Certif

The Clean What Is the Aver

How Does Underwater Welding Work? Will Robots Take

Dry Underwater Welding Conclusion

Wet Underwater Welding

What Is Submerged Welding?

What Are the Types of Welding Joints?

 The Butt Joint

The Lap Joint

The Corner Joint

The Edge Joint

The T-Joint

What Exactly Is Welding 101?

As I’ve mentioned, the actual concept of welding itself is simple.

Practically, it’s the joining of two (or more) pieces of metal together. In e e

Think of the chassis on your automobile. The frame is constructed from se

steel tubes and boxes, all of which have been welded together. They do no
construction.

Usually, welding involves applying heat to the materials to be joined. In do

pieces together as the metal cools again. O en, a filler material is added to

However, just for anyone who is shouting, “that’s not all strictly true!”, ther

It does not have to be metal—some thermoplastics can be joined t

Heat is not always required—some welding methods, such as ultra

cold

What Is The History Of Weldi

Even if you know very little about welding, I am sure you are familiar with t

You know the one, typically a masked man or woman wielding a white-hot

But this is the face of modern welding; it’s been around for much longer.

Here’s a brief historical overview (don’t be put o , it’s interesting).

BRONZE AND IRON AGES

Examples still exist today of Bronze Age gold boxes that had been formed t

These old fabrications (1,000 to 500 BCE) are assumed to have been pound

In addition, Herodotus wrote in "The Histories" that Glaucus of Chios singl

It’s not mentioned what he made, and it’s doubtful he applied for the pate
written record of welding.
MIDDLE AGES

Whether you recall from school texts, or are addicted to Game of Thrones,
blacksmith pounding hot metal with a hammer.

The Middle Ages saw the rise of this forge welding. Metals were heated to h
together by the blacksmith’s blows.

As most Middle Age history seems to consist of men piercing each other wi
skilled in welding had a profitable business.

THE 19TH CENTURY

Humphry Davy discovered the electric arc in 1800, but it was to be over 80
method was created.
This was developed by Nikolai Benardos and Stanisław Olszewski.

In 1881, they found a way to join metal using carbon electrodes with the a

THE 20TH CENTURY

The arc method was continually improved and developed up to the beginn

During the war years, demand naturally increased for welded machines an

Post-war, this led to the development of automatic welding—a faster and m

Further progress included gas tungsten arc welding in 1941, plasma arc we
1961.

Why Is Welding Important Fo

Production?
You don’t have to look far from where you are sitting now, to see the applic

Co ee pots, cupboard door handles, stovetops, even curtain rails. Chances

piece of metal, it has been welded. Industry and manufacturing rely on thi

This is due to the fact that:

It creates the strongest bond between two pieces of metal with sim

It’s cheaper and faster than other joining methods, such as bolting o

In certain applications, welding can be automated—this can reduce

to more consistent quality
 With a strong join comes safety—your car will not fall apart on the fr
will not fail and cover you with hot liquids

Two pieces of metal welded together are o en stronger than trying t

can stress the metal, causing weak spots

Due to these factors, welding is most commonly found in the following ind

Manufacturing—over 270,000 people are employed in the US alone

Transport industry

Construction

Repair and maintenance

What Is The Difference Betw

Soldering And Welding?
Brazing, soldering and welding all have one thing in common—they are de
together. But there are di erences.

BRAZING
This method involves the use of a filler metal to create the bond.

Unlike welding, it does not melt the base metals to make a join.

A blazing torch heats up the filler metal around the joint. Through capillary
reach areas to create a firm bond.

As the base metals are not required to melt, it’s a practical solution for join

SOLDERING
This is a very similar method to brazing, but with one distinct di erence—t

The filler metal in soldering is usually just called “solder” (a tin and lead al
around 390 degrees Fahrenheit.

Brazing involves temperatures above 800 degrees. Soldering is most o en

boards.

What Are The Different Types

As Seba Smith wrote in The Money Diggers (1840), “There are more ways tha

I’m not an expert on felines, so I cannot comment on that statement. Howe

there’s more than one way to weld metal.

Here are the main types:

OXY-FUEL WELDING
Sometimes referred to as gas welding, this is one of the oldest methods, b

The name simply refers to the flame creation mechanism of this welding p

A torch is connected to two di erent gas tanks—one contains pure oxygen

Most o en this “other” fuel is acetylene which has given this method its o
Most o en, this other fuel is acetylene, which has given this method its o

Whatever the fuel used, this is the part which burns and creates the flame.

The 100 percent oxygen raises the temperature of this flame to around

Hot enough to melt metal into a pool and create a weld.

Despite being very simple, this method has virtually disappeared from ind
welding (all discussed below). That being said, it is sometimes used by hob

Pros Of Oxy-Fuel Welding

Electricity is not required—you can be in the middle of a field or dese

Very simple to use

Equipment is o en cheaper than MIG or TIG welding

Adaptability to “cut” metals as well as join

Cons Of Oxy-Fuel Welding

Rough appearance—these welds are less aesthetically pleasing once

they are to be visible

Heats the surrounding area more than arc welding, which may a ect

Limited metal application—can only e ectively be used on low to m

SHIELDED METAL ARC WELDING (STIC

Shielded metal arc welding (SMAW) is also known as flux shielded arc weld
(MMAW).

However, unless you are at an industry conference, you will not o en hear
the-know” call it stick welding.

Hence, that’s how we will refer to it.

Instead of a welding torch, an electrode is used—which looks like a long st

This electrode is covered in another material, or “shield”. Imagine getting a

is the electrode, the paint is the shield.

This electrode is consumable. That is, as welding takes place, it becomes s

requires replacement.

The electrode is connected to a power supply (AC or DC, it doesn’t mat

place.
The stick touches the metal to be welded, and then withdrawn, which crea
through a foot pedal.

As the arc is created, three things happen:

The area being worked begins to melt into a pool

Drops of the electrode fall o under the heat into the weld pool form

The shield coating breaks down and forms a gas

The first two steps are creating the actual weld, the third provides a protec
gases created prevent the weld from being exposed to oxygen. This could o
the weld.

Furthermore, some of this shield (or flux) forms as slag over the welded joi
the weld has cooled and hardened, this slag layer can be removed, to expo

This method is still popular in industry, but due to the time it takes to com
processes. It is generally used in the welding of both iron and steel.

Pros of Stick Welding

Equipment is inexpensive

Additional shielding gases are not required, it is all in the electrode

If done outside, it is less a ected by wind than other methods

Can be used for tight or narrow welding areas

Although usually used for iron and steel, is also useful for aluminum

Cons of Stick Welding

Cons of Stick Welding

As it’s a manual method, the “dipping” action required is di icult to

Needs skill—the electrode has to be at the correct angle to prevent it

Time consuming—the “dipping” action of welding, replacing the ele

Can incur a lot of “splatter”—meaning a messy weld that needs to be

Costly—while equipment is cheap, the above time issue can cause in

GAS TUNGSTEN ARC WELDING (TIG WE

Remember how at the beginning of the article I mentioned welding always

is actually quite simple?

In my opinion, I think that a lot of this is down to the over-explanatory “pro

In this case, gas tungsten arc welding (GTAW). All of the welding types have

Luckily, my favorite two methods have short names—TIG and MIG. Which i

MIG is discussed below, but gas tungsten arc welding is also known as TIG
what I’m going to call it.

The process was perfected in 1941 by Russell Meredith. Although it ma

essence it’s quite simple.

In one hand, the welder holds the welding torch, which has a tungsten tip.
consumable, due to its ability to withstand high temperatures.

This welding torch has two functions:

It connects to the welding machine (typically working on the same p

and therefore the spark

It feeds an inert gas (o en argon) to the weld, to act as a shielding ga

Once the arc is created, the welder should move the torch in a circular mot

the welder’s other hand comes into play.

Filler metal is added to the weld via means of a rod that is “dipped” into th

This is done in an alternating pattern—weld torch goes in, filler rod comes
this action becomes second nature.

Just one thing to bear in mind. The filler rod should not be withdrawn com
“shield” to prevent its oxidation.

TIG welding and MIG welding (below), in my opinion, are the two most sati
 g g y p
enjoyment and final results.

If you want a good example of TIG welding, check out the film “Aliens”—wh
from the Xenomorphs by welding a door shut.

Although, please take more safety precautions than they did (including no

Pros of TIG Welding

A very precise process

Extremely strong welds

Clean, tidy weld beads, suitable for visible display

Satisfaction, once the technique is mastered, is immense

Used on a wide variety of materials, including aluminum, magnesium

A ordable and e icient

Cons of TIG Welding

Slower than using the MIG method below

Takes a little time to develop the correct technique

Involves two hands for the weld and the foot to control amperage

GAS METAL ARC WELDING (MIG WELD

You already know what I am going to say. I’m going to call gas metal arc we
welding (metal inert gas).

I have already confessed that TIG and MIG are my favorite methods.

As explained above, I like TIG due to its neatness and the satisfaction of th

For MIG, my attraction is down to one thing—it is so simple. It is o en con

for beginners because it is so much easier compared to the other methods

I have heard some people compare using a MIG welder to using a glue gun
far o . That’s what makes MIG welding a perfect choice for beginners.
To be honest, the only complicated aspect of MIG welding is the equipmen

Not that they are di icult to use, but the workings inside are quite complex

I always think of it as being similar to my laptop. It can do amazing things,

some magic I am writing this article to be read around the world. I cannot
don’t care as long as it fulfills its function.

Luckily though, I do know how a MIG welder works. That’s probably becau
addictive. So here’s my brief explanation.
The welding gun is where the “magic” happens. The nozzle on the end of t
When it touches the base metal, an arc is formed.

This electrode is consumable: it forms the filler metal for the weld pool. As
continually down the gun nozzle; no other hand is required to feed it.

Furthermore, the shielding gas also comes down the welding gun nozzle, p
absorbing water vapor.

All these actions are controlled by a “trigger” on the welding gun itself. The
welding. You can do it with just one hand. It can also be set to automatic m

That being said, I o en MIG weld with two hands—I find I achieve better ac
better results.

Although the welding gun does do everything, you still require a machine t
and—naturally—you need safety equipment.

MIG welding is the most common form of industrial welding—suitable for u

shielding gas, it is not o en used outside.

Pros of MIG Welding

It is probably the easiest form of welding for beginners

Faster than many other types

Shield and flux are provided by the torch

O en has an automatic function

Low cost—relatively cheap to start up and wastage during use is sma

Can create continuous welds easily

Cons of MIG Welding

Complex equipment sometimes means more things to go wrong

Sometimes can leave deposits which can rust

FLUX CORED ARC WELDING (FCAW)

Flux-cored arc welding is, in many ways, a cross between MIG welding and

Like MIG, it relies on an electrode that is continuously fed through the

the filler metal.

Like stick welding, the electrode, when burned, creates its own shield gase

This is opposed to MIG welding, where a separate supply of shielding gas n

This makes flux-cored arc welding highly transportable.

As it is required to do less work, the welding apparatus is generally smaller

needed.

In certain circumstances, for a “dual-shield” e ect, an external gas can be a

protection.

But in general, this is not the case. If that much protection is required, an a
be used.

Flux-cored arc welding is not recommended for thin materials, ideally no t

Whereas MIG welding can be used on much slimmer metals. Hence, if deal
cored is not an ideal method.

Pros of Flux-Cored Arc Welding

 Can be used quite e ectively outside

Does not require additional shielding gas

Highly portable

Little skill required

Cons of Flux-Cored Arc Welding

Sometimes there are issues with the wire feed mechanism

Generates a lot of smoke during use

Is a hybrid of other methods

What Is The Science Behind W

No, it’s not time to switch o . Knowing how welding works is not only quite
your welding more and produce better results.

I will take you through a simple step-by-step welding process, and let you

As we have already seen, there are many di erent types of welding metho
For this overview, I will use the Alien-preventing TIG method.

Welding For Beginners: The P

THE ARC
As Tim Curry says in the Rocky Horror Picture Show, you need “...that elusiv

Most modern welding—excluding oxy-fuel—uses a spark, or rather an e

For this, you need a power supply (welding machine) to provide the energy
attached to the welding material. The other attaches to the handheld gun.

Electricity always wants to complete a circuit—a little like “Rocket” Rick Me

conductive tip, in the case of TIG, made out of tungsten.

The tungsten is quickly tapped on the base metal and then withdrawn a lit
the air are ionized as the electricity fights to complete the circuit.
Arcs create a phenomenal amount of heat and light (hence safety precauti
more current passed from the power supply, the higher the temperature o

THE MELT

Due to the high temperature of the arc (around 11,000 degrees Fahrenheit
melt. It is important that the arc is moved in a circular motion to create a w

As the two (or more pieces) melt, a process known as welding fusion takes
in e ect, to become one. 

This is why welding is considered the strongest method of connection.

It needs to be observed that the two pieces being joined must have a simil
much earlier than the other resulting in either a failed or cracked weld.
 g

THE FILLER

In TIG welding, the filler is added separately, once “the melt” has started (i
nozzle).

Theoretically, if the two metals being joined are of identical composition a

required.
However, “better safe than sorry” is always a good saying to live by, especi
not weaken the join, only strengthen it.

The filler rod in TIG welding is “dipped” into the weld pool, depositing a sm
stronger bond and fills any spaces or gaps between the two pieces.

It is important that this rod has a similar composition to the metals being j
you have the correct material.

THE SHIELD

As the melt and filler stages are being completed, another important facto

Arc welding requires a shield.

As the name suggests, this protects the weld itself. But as you cannot use a
attached to your weld), gases are used.

These gases in the case of TIG and MIG are passed onto the weld through t

They prevent nitrogen, hydrogen, oxygen and water vapor from conta

If these unwanted elements enter, they can lead to holes (weakening the jo

The main quality these gases need is that they are inert. In essence, they d
essentially, not highly flammable—otherwise, you personally will join the w

The most common gases used are helium, argon, and carbon dioxide. The
type of the weld. In general:

Helium—usually used with non-ferrous metal, is expensive

Argon—cleanest looking and reduces splatter, used with magnesium

Carbon dioxide—one of the most common and cheapest, useful for

In addition, the above gases can be combined into di erent mixes for the i

THE COOL
As you are aware from school, matter exists as solid, liquid or gas.

Actually, just in case any scientists are reading this, that’s not altogether tr
and Bose-Einstein condensates (just saves me from having to respond to i

In welding, the metal is taken to the liquid stage to enable welding fusion.
again to form one solid piece.

Some welders cool the weld with water once completed, known as “quenc
have to, then don’t.”

I understand if time is pressing, and the weld is not “critical” (i.e. if it fails, s
possibility.

Otherwise, leave it to cool down naturally. Reducing the temperature too q

to thermal shock.

The weld will harden a er just a few minutes (but don’t touch it with your
do while it’s cooling. Clean up, pack away your equipment or have a co ee

THE CLEAN
Doesn’t sound like science, but it is.

Studies have shown that, in some circumstances, beauty can be quantified

Cleaning the weld improves its appearance and makes both you and ot
you have taken.

What’s more, if the area is to be painted, having a clean and smooth base w

How Does Underwater Weldi

Before I was into welding, I always wondered how ‘fire’ could work underw
know. It’s not fire, but electrical currents.

There are two types of underwater welding.

DRY UNDERWATER WELDING

This method involves creating a sealed ‘chamber’ around the area to be w
relevant for breathing at that depth.

The welder does not, therefore, need to wear diving equipment.

In this scenario, although deep beneath the water, the welder is still opera
chamber is pressurized).

This makes welding at this depth virtually the same procedure as on the su
room to operate in.

WET UNDERWATER WELDING

In my opinion, this is a wonder of science. As previously mentioned, there
electrical arc, as done out of water.

However, there are a couple of significant di erences. Firstly, as electricity

the electrode required for the arc is waterproof. The most common metho

Secondly, something amazing occurs underwater. I know what you are thi
with by all the surrounding water? Luckily, it’s not. The water creates its ow

As the weld is started, carbon dioxide is created as part of the melting proc
which prevents water from touching the welding area.

Underwater welders are some of the most well-paid in the entirety of the w
required and the dangers involved.

What Is Submerged Welding

Surprisingly enough, it is not another name for the underwater welding dis

The “submerged” part refers to the actual weld. Prior to commencing work
granulated flux—hence it is submerged.

A continuously fed electrode is then pushed into this flux to begin the w

As it is covered in the granules (typically silica or lime), the weld is shielded

In addition, it eliminates splatter, sparks and ultraviolet light. Normally, th

the blanket of flux.

This type of welding is commonly used in industrial applications. It is most

method, completed by a machine.

There are instances where handheld welding is possible, although it is som

What Are The Types Of Weld

Unsurprisingly a joint is where two pieces of metal are joined together to f
Unsurprisingly, a joint is where two pieces of metal are joined together to f

I know I keep mentioning it, but welding is simple. So simple, in fact, that t
I'll list them out below, but keep on reading to learn more about each of th

» Butt Joint
» Lap Joint
» Corner Joint
» Edge Joint
» T-Joint

THE BUTT JOINT

This is probably the most common type of welding joint.

It is when two pieces of metal are joined together, side by side. This includ
same diameter.

Not only is it common, it is also the easiest of all the joints to do. Making it
also known as a square-groove weld—but most people just call it a “butt”.

THE LAP JOINT

This joint is used when two pieces of material “overlap” each other.
This joint is used when two pieces of material overlap each other.

Think of it like this. Take two square drink coasters and place one on top o
about an inch to the right, leaving the other one stationary. Where they me

If added strength is required, these two metals can be welded both on the

A joint like this is o en used where the two surfaces have di erent thic

If you’re a healthy type and attend the gym frequently (unlike me,) check o
have lap joints.

THE CORNER JOINT

Corners of equipment o en receive the most “punishment” during their lif

joints to be repaired or replaced frequently.

The joint is made so that the two metals are pushed together to form a righ
When welding, the weld goes on the outside of the joint, not the inside. Ty
and square frames.

THE EDGE JOINT

Most o en used when one of the metal parts has edges that are flanged. Im
on a flat piece of steel.

Joints like these o en require filler metal to ensure that they remain as str
surface area where the two parts actually meet.

THE T-JOINT
As the name suggests, a joint that, when viewed from the side, looks like a
identical steel measuring 2 inches high by 1 inch wide.

Lay one piece on a work surface with the 2-inch side flat to it. Take the othe
side abutting it.

What Materials Are Used In W

As we have seen, welding does require the use of other materials, in additi

Here are three of the most common types:

COVERED ELECTRODE
These are steel electrode rods surrounded by a flux material.

This electrode works to both create the arc and act as the filler metal.

The flux coating reacts with the heat to provide a gas shield. The covered e

GMAW SOLID WIRE

Used in MIG welding, this wire is small in diameter and is continuously fed

These are supplied on spools, for home and small business use, or on large

As they contain no protective flux, an external supply of shielding gas is req

SAW FLUX

Earlier, we discussed submerged arc welding. SAW flux is the granulated m

weld. Most o en, these are supplied in a large sack format.
Di erent types are available, depending on the heat being used and/or me

How Do You Check The Quali

Once you have completed your weld, you inspect it, and yes, the two piece
The question is—will it stay that way?

If you have just re-attached an arm to your metal statue of Wolverine, and
issue (well, except to Wolverine).

However, if you’ve replaced a metal ladder rung, and it fails while attachin
more serious.

Checking the quality of a weld is always something I recommend, even

You want the satisfaction of knowing your handiwork is going to last. Henc

Generally speaking, there are three types of quality assurance—visual, non

destructive.

Unless you work in the industry, you are unlikely to do any other quality ch
included brief details on the other two. Knowledge is power, right?

VISUAL
Many issues can be spotted simply by inspecting the weld. Or, if someone e
more important to examine their work.

Visual checks are the easiest way to check quality, and require no equipme
looking out for.

Existence Of Waste
How “clean” is the weld? It should be free from any extraneous materials. F

Even if some is generated during welding, it can easily be removed via pee
If other elements are obvious (dirt, metal shavings, small animals) it mean
cleaned before welding. A dirty weld is a weak weld.

Allocation Of The Weld

There should be an even distribution of the welding material in the join wi

Porous Holes
If small holes have appeared in the weld, alarm bells should start to ring. T

This will radically reduce the strength of the weld, and should be rejected
of, or insu icient, shielding gas during the welding process. It means that o
enter the weld pool.

Gaps
Where the metals meet, the joint should be tight and without visible gaps.

This has usually been caused by poor preparation and failure to secure the

Does It Leak?
If the weld has been done on an item that can (not necessarily by design) h

Mix a little soap detergent in water and tip into the welded object. If water
insu icient.

NON-DESTRUCTIVE TESTING
These are ways to check the integrity of the weld, which still leaves it usab
some specialized equipment.

Radiographic—using X-rays which can expose defects beneath the s

Magnetic particle—an electric current is passed through the weld, m

where the electric is leaking, i.e. a fault in the weld

Penetrating liquid—dyed liquid is placed on one side of a joint and

capillary action will move the dye to another part of the weld

DESTRUCTIVE TESTING
As the name suggests, this test pushes the weld to literally breaking point.

This may initially sound a little strange. If the weld breaks past its intended
broken and is rendered useless.

Hence, this method is only used in specific areas, mainly:

Sample testing—a welder may supply an example of their work for

checks the integrity of the weld—hopefully, successfully leading to fu

Qualification—some welding examinations may include testing the

become qualified

Investigation—if an accident has occurred from a failed weld, simila

be tested to see if they are at fault

The tests for these reasons include:

Fillet break—used on welds that have been joined on only one side;
to see how much pressure is required for it to break

Transverse break—welds are pulled apart laterally to test integrity

Bend break—the weld is bent until failure occurs

What Equipment Is Used In W

If you are anything like me, it’s all about the equipment.
Naturally, it’s essential, as without it there would be no welding.

But there’s nothing as satisfying as going into your garage or workshop an

Here are the most important pieces for the welder:

WELDING MACHINES
Theoretically, it is possible to use a car battery as a power source, although
welding machines provide the power supply for the welding process.

Plugged into the mains, these machines convert the input power into a
for welding.

Many of these convert the AC into DC through an inverter.

DC current can produce less splatter when welding, however, AC is require

In addition, it is possible to buy welder generators. These can supply the c

gasoline-powered internal combustion engine.

These are particularly handy for use where there is no mains supply, for ex

Furthermore, some welding machines include a wire-feed system. This pro

consumable electrode to create the arc and provide filler metal (for examp

REGULATORS
If you enjoy having a gas grill cookout in the summer, chances are you alre

We have already looked at the importance of shielding gas in welding. How

directly to your torch and turn the flow on, all the gas would be used in aro

The regulator brings down the pressure to a usable level, allowing a steady
weld.

In many cases, the regulator will have two gauges. One shows the pressure
and the other the flow rate to the welding gun. The flow rate can be altered

This allows you to set the correct rate for your work. Thick wire and dense
versa.

WELDING CONSUMABLES
The consumables are those materials which become used up as the weld p

In general, these consumables form the heat source, act as a filler metal an
with shield gas.

They include such things as covered electrodes (for stick welding) and

They can be consumed by using a welding gun (in the case of MIG) or as a s

Choosing the correct consumable depends on:

Style of welding—TIG, MIG, stick etc

The metal being used

Strength required by the wel

WELDING TORCHES
Sometimes, welding torches are referred to as “guns”. This has become qu
pretty much interchangeable.

Usually, however, guns are distinguished by the fact that they have a trigge

The welding torch has numerous functions, including:

Striking and maintaining the electric arc

Creating and “shaping” the weld

Providing shielding gas in certain welding methods

Choosing the correct torch depends on its application. Aspects to consider

 The style of welding (TIG, MIG etc.)

The current used in the weld

Size of electrodes being used

Form of gas shielding

It’s not surprising to discover that these torches can become hot during us
either through air or circulating water.

SAFETY EQUIPMENT

If anything, safety equipment is probably one of the most important factor

have given the topic its own section below.

Welding Safety
 g y
Let me be honest.

Wielding a torch in your hand that can generate temperatures up to 11,000

you will ever do.

However, as long as you are sensible, there is no reason that it should be a

Furthermore, I find something about this “theoretical danger” quite appea

The idea of doing something that other people would never consider g

That being said, welding can involve quite a few hazards, and therefore po
Common occurrences include:
Arc eye—basically sunburn to the cornea of the eye, due to exposure
known as the welders eye.

Combustible burns—clothes can catch fire leading to burns

Respiratory problems—inhaling chemicals and fumes can create ch

idiopathic Parkinson's disease

Electric shock—when two parts of the base metals touch

Despite the above, wearing the correct safety equipment when welding ca
risks.

WELDING SAFETY GEAR

The items listed below are essential when welding. Never start your projec
also read our checklist for safety gear if you want a dedicated resource.

Welding Clothing
It’s not just about looking like a professional, it’s acting like one too. Weari
simplest way to protect yourself from common burns. 

As welding is definitely a process that is going to make you warm, there ca

and a T-shirt to keep cool. Do not do this.

Exposed skin can become burnt from the heat or fire, or just through expos
yourself completely is the best way to stay safe.

At the very least, if you have no purpose-made welding clothing, wear non
thick, closely woven cotton shirt, for example.

However, ideally, you should invest in proper fireproof welding clothes. Un

th li ht i ht d ll th b d t “b th ” k i
these are now lightweight and allow the body to “breathe,” keeping you co

Look for—at least—a jacket, trousers, and gloves. Many companies now o
clothing you require in one box.

Welding Glasses

These glasses, or goggles, protect the eyes from ultraviolet and infrared lig
into the eyes.

Side shields can prevent light from seeping in from the corners, which can

These glasses contain very dark filters. They allow the welder to see the we
them safe.
O en glasses are designed for specific types of welding. So, if you are arc w
fuel.

Frequently, the glasses are worn under the actual welding helmet.

Welding Helmets

Welding helmets o er full face protection, as opposed to just the eye prote

These, too, include filters that prevent ultraviolet and infrared light from e
f fl i k h i l Th bi d ith l th if
of flying sparks or chemicals. They are o en combined with leather caps if

You may have seen the typical welders “nod” to bring down the helmet vis
visor is too dark to see through to prepare the weld, it can only be seen wh

To counter this, some companies now provide clear visors that darken aut
This allows the weld to be first prepared with the mask down.

In the United States, it is recommended that the welding helmet achieves

would, therefore, suggest you check that your helmet meets this standard

Welding Respirators
Most people know of the dangers of looking at a welding arc, less understa
the fumes.

We all now understand the dangers of smoking, but many welders o en ig

create even greater problems.

Out of all the mistakes I see welders make, failing to use a respirator is the

Not only can it create short term side e ects, such as coughing and bre
be fatal.

Respirators range from the very basic (disposable) to the advanced (air-fed
requirement depends on the type of welding that is being completed.

Many of these respirators are designed to be worn beneath a full welding m

Is Welding A Good Career Op

If you dislike heat, are useless with your hands and dream of a career in a c
awful career choice.

However, if you like being “hands-on,” want a job with great employment p
things that only a select few can, then it could be the ideal career.

In the U.S. alone, there is forecast to be a shortage of around 270,000 weld

finding an available position should not prove too di icult.

WHAT ARE THE PROS OF A WELDING C

Salary

As Marco Rubio said in 2015, “We need more welders and less philosophers.

I am not aware of a wealthy philosopher, however, I do know some very co

good pay prospects.

Employed Or Self-Employed
Welding is a career that can be done either working for a corporation or o

Many self-employed welders have the freedom to work as and when they c
want to specialize.

Conversely, other welders prefer the “company” environment, with the be

Variety Of Work
Welding is involved in so many industries, meaning that no two welding jo
welding is used in:
h l
welding is used in:
The military

Construction

Automotive industry

Oil and gas

Manufacturing

Undersea

Space exploration

It is, therefore, perfectly feasible to combine an interest in welding with an

Doing Something You Love

Many people never work as a welder, but it is their hobby.

As pastimes go, I consider it one of the most rewarding.

If welding is your passion, surely there can be nothing better than getting p
doing.

WHAT ARE THE CONS OF A WELDING C

Comfort

Welding isn’t for everyone. It can be noisy, hot and dirty. Plus, it can mean
in the wet or cold.

Injury
Even with a “safety-first” attitude, accidents can happen. Not only is the in
you from working for a while.

Working Hours
Working Hours
As working to a deadline is o en a feature of welding, this can involve long
can mean working nights too.

How Do I Become A Welder?

If you are planning on becoming a hobbyist welder, there are a few options

Find a local welder and see if they are willing to give you some time—
welding
Watch approved online tutorials

Check local universities and community colleges for available course

However, if you’re considering welding as a career, here are my recommen

HIGH SCHOOL
Take math, shop and science lessons; some schools even have welding cla

BECOME TRAINED
Some employers may train you “on-the-job,” while others o er full appren

Colleges, universities,  best technical schools, and the military can all o er
be employed if you have some formal training as a basis.

OBTAIN A CERTIFICATION
Some employers have their own certification and training programs, but th
that particular company.

To make yourself available for the most opportunities, look toward ob

Certified Welder accreditation.

This certification is open to all, regardless of current educational qualificat

In this examination, your ability to complete welding tasks required in the

refinery industries, is tested.

In addition, certain industries provide their own certifications, dependent

are:

American Petroleum Institute—with emphasis on materials related

American Society of Mechanical Engineers

What Is The Average Wage O

According to research conducted by PayScale, the average wage for a weld
t t l l f $44 000
amounts to an annual salary of $44,000.

If you are a total newbie, the entry-level salary is about $35,000. However,
take salaries much higher.

For example, if underwater diving is your niche, sub-surface welding can e

with the top ten percent enjoying over $100,000.

Will Robots Take My Welding

We have all heard about advances in artificial intelligence, and seen movie

It seems like there is a certainty that whatever occupation we are in, weldi
machine.

However, the outlook may not be quite that bleak. To be fair, robots are alr

Th h b d i th 1980 i t ti d ti i l f