Welding is a fabrication process that joins materials, usually metals or thermoplastics, by using

high heat to melt the parts together and allowing them to cool, causing fusion. Welding is distinct
from lower temperature techniques such as brazing and soldering, which do not melt the base metal
(parent metal)

1. Form a Plan
For proper weld preparation, it’s important to have a plan before
getting started.

2. Cut, Fit, Bevel

Once your plan is in place, the second step in preparing metal for
welding is often cutting, fitting, and beveling the base material

3. Prep, Clean the Surface

Once the material is cut and beveled, it’s time to prepare the
surface for the initial welding pass. Removing any mill scale,
chemicals, contaminants, and coatings from the base material
helps ensure proper weld penetration and eliminate impurities,
porosity, and inclusions.

4. Choose the Optimal Grit

A common misconception is that a coarse abrasive will always get
the job done faster.

5. Select the Right Abrasive Profile

Several abrasive profiles are available that can make the job easier
or harder.

Wire wheels are much more resistant to loading but do not remove
base material. That makes them a good choice for removing surface
contaminants and coatings without affecting the base metal.

Why do we need to prepare edges of materials?

 Edge preparation is necessary primarily for two reasons. The first is strength. The
welded joint will be stronger in tension if the weld itself is in line with the pulling force.
Edge preparation allows us to deposit the filler in the same plane as the base material

What type of edge preparation is needed?

Edge preparations usually require a specific bevel angle. You may need to prep one or
both workpieces, and they create what is known as a V-groove or single bevel. The
edges can touch, or they can be spaced to a specific tolerance to create a root opening

What are the different types of edge preparation?

 Closed sq. butt joint up to 2 to 3 thick sheet.
 Open sq. butt for 4 to 6 mm.
 Single 'V' bevel for 6 on wards, say up to 1 mm or so.
 Double 'V' for 18 mm on wards.
 Single 'U' bevel from 20 mm to 30 mm.
 Double 'U' from 30 to 50 mm.
 Single 'J' from 50 mm to 75 mm.
 Double 'J' from 75 mm on wards.
 What are consumables in welding?

 In Welding, substances called filler materials or consumables are used. As the
name implies, these substances provide a filler or a body of molten materials that
provides a strong bond to be formed between the base metals used.
What are the materials and consumables in SMAW?
SMAW Components
 Arc welding power source (welding machine)
 Electrode lead cable.
 Electrode holder.
 Leads.
 Cables.
 Cable connectors.
 Ground clamp.
 Chipping hammer.
 What is the best PPE for welding?
 A welding helmet, welding beanie, face shield, safety glasses, and/or safety
goggles may all be required throughout the day in order protect a welder's eyes
 What are the safety tools for welding?
  Some of the PPEs required for welding include helmets, gloves, jackets or
aprons, boots, HEPA-filtered or supplied-air respirators, hearing protection like
earmuffs or earplugs, and safety glasses or goggles.
What are the 10 safety rules when welding?

10 Welding Safety Rules

 Conduct in a designated safe location.
 Protect yourself from fire hazards.
 Consider the risks.
 Maintain your equipment.
 Protect yourself with the correct PPE.
 Check for ventilation.
 Protect yourself from fumes and gases.
 Protect other workers.