AMT 125

Materials Construction and Repair

II
MIDTERM
WELDING
WELDING

• Welding is the permanent joint joining of two metals, it

actually melts two pieces of metal together to make a very
strong singular piece.
• Welding is a fabrication process that joints materials
usually metals by causing fusion
Personal Protective Equipment for Welding
• Welding produces harmful bright light, heat, sparks, sharp pieces
of metal and noxious gases. Some basic protective materials are
a hood with a dark protective eyeglass to prevent injury to the
eyes and upper body
 a particle mask to filter breathing air,
 leather gloves,
 nonflammable long-sleeved shirt,
leather shoes
 and jeans.
 leather apron to protect skin from being burned by flying metal
shavings.
Basic Tools for Welding
• Hammers are used to help align materials being welded and to
break off frayed pieces of metal.
•  A steel brush is an excellent cleaning tool and is an essential
part of the welder’s equipment.
• Sandpaper or an electric grinder is used to properly fit mitered
joints and smooth out a rough weld joint.
• Large pliers are important to move and adjust hot metals.
• A square is used to align metal into square corners.
• A hacksaw, power saber saw or miter saw with an abrasive
cutting wheel can be used for cutting metal to the proper size
Welding Equipment

• Welding Machine
• Welding Electrode
• Electrode holder
WELDING MACHINE
• A welding machine is used to join two metal pieces
together.

WELDING ELECTRODE
• Electrode is used to conduct current through a work piece to fuse two
pieces together.
• Compose of Core rod it carries welding current and becomes part of
the weld
And Flux coating it produces a shielding gas and helps from a slag
 WELDING ELECTRODE

E7018-X
E Indicates that this is an electrode
70 Indicates how strong this electrode is when welded. Measured in thousands of pounds per
square inch.
1 Indicates in what welding positions it can be used.
8 Indicates the coating, penetration, and current type used. (See Classification Table below)
X Indicates that there are more requirements. (See Additional Requirements below)
WELDING POSITIONS
1 Flat, Horizontal, Vertical (up), Overhead
2 Flat, Horizontal
3 Flat
4 Flat, Horizontal, Vertical (down), Overhead

Flat Position - usually groove welds, fillet welds

Horizontal - Fillet welds, welds on walls (travel is from side to side).
Vertical - welds on walls (travel is either up or down).
Overhead - weld that needs to be done upside down.
CLASSIFICATION TABLE
Class Electrode Coating Penetration Current Type
Exxx0 Cellulose, Sodium Deep DCEP
Exxx1 Cellulose, Potassium Deep AC, DCEP
Exxx2 Rutile, Sodium Medium AC, DCEN
Exxx3 Rutile, Potassium Light AC, DCEP, DCEN
Exxx4 Rutile, Iron Powde Medium AC, DCEP, DCEN
Exxx5 Low Hydrogen, Sodiu Medium DCEP
Exxx6 Low Hydrogen, Potassium Medium AC, DCEP
Exxx7 Iron Powder, Iron Oxide Medium AC, DCEN
Exxx8 Low Hydrogen, Iron Powder Medium AC, DCEP
Exxx9 Iron Oxide, Rutile, Potassium Medium AC, DCEP, DCEN
VIDEO
 ELECTRODE HOLDER
• An  electrode  holder,  commonly  called  a  stinger,  is a
clamping device for holding the electrode securely in any
position. The welding cable attaches to the holder through the
hollow insulated handle. The design of the electrode  holder
 permits  quick  and  easy  electrode  ex-change.  
• Electrode  holders  are  made  in  different  sizes,  and
manufacturers  have  their  own  system  of  designation.
Each holder is designed for use within a specified range of
electrode diameters and welding current. You requirea larger
holder when welding with a machine having a300-ampere
rating than when welding with a 100-ampere machine.

VIDEO
WELDING PROCESS
• The number of different welding processes has grown in
recent years. These processes differ greatly in the
manner in which heat and pressure (when used) are
applied, and in the type of equipment used. There are
currently over 50 different types of welding processes;
we’ll focus on 3 examples of electric arc welding, which is
the most common form of welding.
The most popular processes are

• Shielded metal arc welding

• Gas metal arc welding
• Gas tungsten arc welding

 All of these methods employ an electric power supply to create

an arc which melts the base metal(s) to form a molten pool.
Shielded Metal Arc Welding (SMAW)
 Shielded Metal Arc Welding (SMAW)
• SMAW is a welding process that uses
a flux covered metal electrode to carry
an electrical current. The current forms
an arc, The electric arc creates enough
heat to melt both the electrode and the
base material(s).
• Molten metal from the electrode
travels across the arc to the molten
pool of base metal where they mix
together. As the arc moves away, the
mixture of molten metals solidifies and
becomes one piece. The molten pool
of metal is surrounded and protected
by a fume cloud and a covering of slag
produced as the coating of the
electrode burns or vaporizes
Shielded Metal Arc Welding (SMAW)

• SMAW is one of the oldest and most popular methods of

joining metal. Moderate quality welds can be made at low
speed with good uniformity. SMAW is used primarily
because of its low cost, flexibility, portability and
versatility. Both the equipment and electrodes are low in
cost and very simple. SMAW is very flexible in terms of
the material thicknesses that can be welded
Shielded Metal Arc Welding (SMAW)

Some of the biggest drawbacks to SMAW are

• (1) that it produces a lot of smoke & sparks,
• (2) there is a lot of post-weld cleanup needed if the
welded areas are to look presentable,
• (3) it is a fairly slow welding process
• (4) it requires a lot of operator skill to produce consistent
quality welds.
Arc Welding Materials
Using an electric arc welder is probably what most of us imagine when
we think of welding -- bright light and lots of sparks. This type of welding
uses high-voltage electricity to generate the heat needed for welding.
The basic arc welding materials include an electric arc welding machine,
handheld welding rods that melt and are used to help join the metals,
grounding wire and clamp and electric power cords to deliver the
electricity to the welding site.

Gas Welding Materials

TIG and MIG styles of gas welding use electricity and stored pressurized
gas. TIG uses a welding rod; MIG uses a continuously feeding wire
instead of a handheld rod. Oxyacetylene welding uses a high
temperature gas torch and welding rods, but no electricity. The basic gas
welding materials include torches, pressurized gases stored in tanks,
TIG and MIG welding machines and welding rods or wire. Each type of
gas welder has commercial, household and hobby uses.