An integrated lesson

 Introduction
 What is Arc Welding?
 Why is Welding Important?
 Why Learn to Weld?
 Basic Electricity and the Science of Welding
 Electricity
 Energy Transfers
 Changes of State
 Chemical Reactions
 Welding Safety
 Careers in Welding

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 Arc welding is a process used to join two pieces
of metal together.
 How does it work?
 A welder creates an electric arc that melts the metal
and filler rod to create a pool of molten metal that
hardens to fuse the two pieces of metal together.
 Why is welding important?
 Many of the things you use need to be welded.
 Your parent’s car
 Power line towers
 Your school desk
 Your bicycle www.topspeed.com

dcist.com assembly.state.ny.us
www.cunninghamcycles.com
  Why Learn to Weld?
 Welding can help build a successful career to earn
money to buy the things you want.
 Skilled Welders are in high demand.
 Welding is challenging and high tech.

www.universalwelding.com
www.weldingschools.com
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 Voltage – The electrical potential or pressure
that causes current to flow
 Measured in Volts
 Current – The movement of charged particles
in a specific direction
 Measured in Amps DC+
DC -
 Polarity
 DC- (Direct Current
Electrode Negative)
 DC+ (Direct Current
AC
Electrode Positive)
 AC (Alternating Current)
 The electricity flows from the power source,
through the electrode and across the arc,
through the base material to the work lead and
back to the power source

 Circuit – click on the link

to learn more.
Circuit Info.
 Use the following links to learn how electricity
works in a circuit
 Conductors, Insulators, and electron flow
 Current and Voltage in a Circuit
 Resistance
 Ohms Law
 The electron flow you just learned about is
what creates the arc in arc welding.
 This is a form of electrical energy
 How do we use that electrical energy to fuse metals
together?
 The energy transfers that take place in welding

Electrical The arc created by the

electric current is
converted into heat
Thermal because of the
resistance of electron
flow. The heat melts
the metal to fuse it
together.
 Here are some places to look to learn more
about energy and energy transfers.
 Forms of Energy
 Energy Transformations
 Changes of State and Chemical Reactions
 During the welding process the metal changes states
or forms.
 What are the states of matter?
 Solid
 Liquid
 Gas
 Plasma

Click here to learn more about the changes of state

 Changes of State and Chemical Reactions
 So what changes of state occur during welding?
 Initially the metal is a solid
 When the arc starts the solid is converted into a liquid
 Some of the liquid is converted into a gas vapor
 When the arc stops the liquid cools to form a solid
again – this is the newly formed weld joint

Solid Liquid Solid

(gas vapor)
 Changes of State and Chemical Reactions
 Chemical Reactions
 During the welding process certain chemical reactions
take place.
 Hydrogen, Oxygen, and Nitrogen can react in the weld
puddle and cause changes in the structure of the weld
weakening the weld.

pt.chemicalstore.com
 Because of the chemical reactions, energy transfers, and
electricity involved in welding proper safety must be
addressed
 Welding can be safe when sufficient measures are
taken to protect yourself and others from potential
hazards
 Students should read and understand the following
before welding:
 Warning Labels
 Material Safety Data Sheets (MSDS)
 Students should also be familiar with the following
information
 ‘Safety in Welding, Cutting, and Allied Processes’ (ANSI Z49.1)
 Lincoln Electric’s ‘Arc Welding Safety’ (E205)
http://www.lincolnelectric.com/knowledge/training/weldcurriculum.asp
 Understand and follow all warning labels
found:
 On welding equipment
 With all consumable packaging
 Within instruction manuals

www.jpbrandit.com
http://www.lincolnelectric.com/knowledge/training/weldcurriculum.asp
 Material Safety Data
Sheets (MSDS) are:
 Required by law and
OSHA
 Created by the
manufacturer of a
product per OSHA
guidelines
 Designed to inform
users
 Shipped with every box
of consumable product
 Available free online at:
www.lincolnelectric.com/produc
ts/msds/

http://www.lincolnelectric.com/knowledge/training/weldcurriculum.asp
 MSDS outlines a
product’s:
 Identity and
composition
 Potential hazards
 Safe use
 Handling
information
 Manufacturer
contact information

http://www.lincolnelectric.com/knowledge/training/weldcurriculum.asp
  Protect yourself and
others from
potential hazards
including:
 Fumes and Gases
 Electric Shock
 Arc Rays
 Fire and Explosion
Hazards
 Noise
 Hot objects

http://www.lincolnelectric.com/knowledge/tra
ining/weldcurriculum.asp
 Fumes and gases can be
hazardous to your health
 Keep your head out of the
fumes
 Use enough ventilation,
exhaust at the arc, or both,
to keep fumes and gases
from your breathing zone
and the general area
 See product labeling and
MSDS for ventilation and
respirator requirements

http://www.lincolnelectric.com/knowledge/training/weldcurriculum.asp
 Electric shock can kill
 Do not touch live
electrical parts
 Primary Voltage –230,
460 volt input power
 Secondary Voltage – 6
to 100 volts for welding
 Insulate yourself from
work and ground
 Follow all warnings
on welding equipment

http://www.lincolnelectric.com/knowledge/training/weldcurriculum.asp
 Welding sparks can cause
fires and explosions
 Sparks and spatter from
the welding arc can spray
up to 35 feet from your
work
 Flammable materials
should be removed from
the welding area or
shielded from sparks and
spatter
 Have a fire extinguisher
ready
 Inspect area for fires 30
minutes after welding

http://www.lincolnelectric.com/knowledge/training/weldcurriculum.asp
Welders must wear
protective clothing for
 Protection from sparks, spatter
and UV radiation
 Insulation from electric shock

 Protective clothing
includes …
 Fire-proof clothing without
rolled sleeves, cuffs or frays
 Work boots
 Welding gloves, jackets, bibs,
and fire-proof pants
 Welding cap, helmet and
safety glasses
 Ear protection – ear plugs and
muffs

http://www.lincolnelectric.com/knowledge/training/weldcurriculum.asp
 Education  Careers
 Penn College of Tech  American Welding
nology Society
 Penn College  Career Guide
Welding Video  Welding Jobs
 Welding Schools

pro.corbis.com
www.sun-tech.org
 Here are some possible areas you can start a career
in welding
 Racing
 Engineering
 Farm
 Auto Technician
 Sculpting
 Maintenance
 Iron worker
 Robotics
 Production welder
 Fabricator
 And many more…
 Do you want to learn more about welding and
how to weld? If so, go to the link below for
more information on how to weld.
 This is to be used if your school has access
 http://www.lincolnelectric.com/knowledge/t
raining/weldcubrriculum.asp
 http://www.lincolnelectric.com/knowledge/t
raining/weldcurriculum.asp
 http://www.weldinginfocenter.org/sci_tech/i
ndex.html
 http://www.pct.edu/degreesthatwork/weldi
ng.htm
 http://www.allaboutcircuits.com/vol_1/index
.html
 All photographs are cited next to photograph