Arc Welding

Basic Safety
 Warnings
• Welding can be safe when proper measures
are taken to protect yourself and others from
potential hazards.
• Understand and follow all warning labels
found on equipment and with all
consumables.
 Potential Hazards
• Protect yourself and others from potential hazards
including:

– Fumes and Gases

– Electric Shock
– Arc Rays
– Fire and Explosion Hazards
– Noise
– Hot objects
– Welding Sparks
 Fumes and
Gases
•Welding fumes can be harmful
to the welder causing
implications such as:
oIrritation of the
respiratory tract
oMetal fume fever
oSlightly increase the risk
of lung cancer
•Use enough ventilation,
exhaust at the arc, or both, to
keep fumes and gases from
your breathing zone and the
general area
•Use a respirator if needed or
required by the process.
•The ventilation system must be
on while welding at all times.
 Electrical
Shock
•Electric shock can kill
•Do not touch live electrical
parts
Primary Voltage –208 - 240,
416 - 480 volt input power
Secondary Voltage – 6 to
100 volts for welding
•Insulate yourself from work and
ground
•Follow all warnings on welding
equipment
•Wear insulated clothing
•Always shut off machinery
when done and roll the cords up
neatly
•Do not make repairs yourself,
alert your instructor
immediately!
U.V. Rays
•Welding will produce ultraviolet rays
that are harmful to the human eye and
skin. Proper protection is needed to
avoid bodily harm.
•Arc rays are ten times brighter than
the sun and can injure eyes and burn
skin
•Precaution must be taken to protect
your eyes and skin from UV radiation.
The welding arc is brighter than the
sun
•Wear correct eye and body protection
o10 shade helmet
oSafety Glasses under the
helmet
oGloves
oArm and Body Protection
Jacket
Shoulder Covers
Coveralls
 Fire Hazards and Material Safety
• 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
• Always clean painted materials
• All welding booths should be cleaned thoroughly
• Have a fire extinguisher ready
• Inspect area for fires 30 minutes after welding
• Watch for sharp metal edges
• Cool all welded metal in the water tank.
 Ear Protection
• Loud noises can damage your hearing
• Keep loud noises at a safe level by using proper
hearing protection such as:
– Ear plugs
– Ear muffs
 Protective
Clothing
•Welders must wear protective
clothing for
oProtection from sparks, spatter
and UV radiation
oInsulation from electric shock

•Protective clothing includes …

oFire-proof clothing without
rolled sleeves, cuffs or frays
oWork boots
oWelding gloves, shirts jackets,
bibs, and fire-proof pants
oWelding cap, helmet and safety
glasses
oEar protection – ear plugs and
muffs
oMost importantly safety glasses
are to be worn at all times in the
shop
 Improper Protective Clothing
• List and describe
what is wrong
in this picture
Basic Electricity and Welding

Arc Welding
Basic Safety
Arc Welding Circuit and Concept
•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.

Identify all the above parts for the arc welder,

describe the function of each part, and determine
each of the parts safety aspects.
 Electrical
Concepts DC - DC +

•Voltage – The electrical potential

or pressure that causes current to
flow
oMeasured in Volts
•Current – The movement of
charged particles in a specific
direction
oMeasured in Amps
•Polarity
oDC- (Direct Current
Electrode Negative) AC
oDC+ (Direct Current
Electrode Positive)
oAC (Alternating Current)

•ALWAYS REMEMBER
THAT VOLTAGE WILL
HURT BUT AMPERAGE
CAN BE FATAL
Electrical Lead
Condition
•Before starting an operation, always
check the condition of all electrical
leads.
•Cracked and worn leads can lead to
fatal shock.
•All electrode holders or “stingers”
should be in tack and not cracked or
missing pieces.
•All plugs and outlets should be in
tack. Never set-up a welder with a
broken plug or into a broken outlet.
Never operate a welder with splices
showing in the leads.
Shielded Metal Arc Welding

SMAW
SMAW Process
 SMAW Key Parts
• Electrode Holder: Also known as the “stinger” Handle-like tool
that holds the electrode while welding.
– Never hold this part with your bare hand while welding.
• Ground Connection: Also known as the “workpiece connection
clamp” that connects to the work to complete the electrical circuit
• Power Source: Where the welder plugs into
• Amperage Scale: Determines the amount of “heat” or power the
welder will operate at.
• Polarity Switch: Setting that determines how the electrons will flow
during the welding process.
• On / Off Switch: Turns the welder on / off. Make sure the switch
function properly at all times.
 SMAW Principles
• The American Welding Society defines SMAW
as Shielded Metal Arc Welding
• SMAW:
– Is commonly known as ‘Stick’ welding or manual
arc welding
– Is the most widely used arc welding process in the
world
– Can be used to weld most common metals and
alloys
 SMAW Welding Circuit
• Current flows through the electrode cable, to the electrode
holder, through the electrode, and across the arc
• On the work side of the arc, the current flows through the
base material to the work clamp and back to the welding
machine
 SMAW Process

Identify all the above segments for the SMAW process,

describe the function of each segment, and determine if any
safety aspects exist.
 The Electrode
What is it?
• Is a consumable - it gets melted during the welding process
• Is composed of two parts
– Core Rod (Metal Filler)
 Carries welding current
 Becomes part of the weld
– Flux Coating
 Produces a shielding gas
 Can provide additional filler
 Forms a slag
Electrode
Classification
•Electrodes are classified
by a numbering system
•E6013
oE = Electrode
o60 or first two
numbers = Tensile
strength (thousands
of pounds
o1 or third number
= Welding position Pictured above are E-7018 electrodes. Identify
o3 or fourth number what the tensile strength is for this electrode.
= Welding current
type and depth of
weld penetration.
Electrode
Classification
Third Digit
•Third Digit
E_ _ 1 _ = Usable in
all directions
E_ _ 2 _ = Usable in
flat and horizontal
positions only
E_ _ 4 _ = Usable
for vertical down Pictured above are E-6011 electrodes. Identify
only what each digit resembles up to the third digit.
Electrode
Classification
Fourth Digit

•Fourth Digit
E_ _ _ 0 = DC reverse polarity
only
E_ _ _ 1 = AC and DC reverse
polarity
E_ _ _ 2 = AC and DC straight
polarity
E_ _ _ 3 = AC and DC
E_ _ _ 4 = AC and DC
E_ _ _ 5 = DC reverse polarity
E_ _ _ 6 = AC and DC reverse Pictured above are E-6013 electrodes. Identify
polarity what each digit resembles.
E_ _ _ 8 = AC and DC reverse
polarity
 The Arc
•An arc occurs when the electrode comes
in contact with the work-piece and
completes the circuit … like turning on a
light!

•The electric arc is established in the space

between the end of the electrode and the
work

•The arc reaches temperatures of 10,000°F

which melts the electrode and base
material

•Don’t look at the arc without proper eye

protection.

•Wear proper body protection. The UV

rays will cause bodily harm.
Arc burning off the electrode
Weld Puddle
•As the core rod, flux
coating, and work
pieces heat up and
melt, they form a pool
of molten material
called a weld puddle
•The weld puddle is
what a welder watches
and manipulates while
welding
•Don’t touch the hot
puddle!!! The metal is
hot!!!
Shielding Gas
Shielding Gas
•A shielding gas is formed 4
when the flux coating
melts.
•This protects the weld
puddle from the 3
atmosphere preventing 2
contamination during the
molten state
•Don’t touch the metal!!!
The metal is hot!!!
•Shielding gas can cause The shielding gas protects the molten puddle
bodily harm. Be sure from the atmosphere while stabilizing the arc
proper ventilation is being
used.
Solidified
Weldment
•As the molten weld
puddle solidifies, it
forms a joint or
connection between
two pieces of base
material
•When done properly
on steel, it results in a
weld stronger than the
surrounding base metal
•Don’t touch the
metal!!! The metal is
hot!!!
Slag
•Slag is a combination of the
flux coating and impurities
from the base metal that float
to the surface of the weld.
•Slag quickly solidifies to form
a solid coating which slows
the cooling rate of the weld
•The slag can be chipped
away and cleaned with a wire
brush when hard
•Don’t touch the metal!!! The
metal is hot!!!
•Slag can be dangerous when
This welder chips the slag off of a weld during
being removed. Wear the
the repair of railroad tracks
proper safety protection.
OXY ACETYLENE

SET-UP
 Terms and Definitions
• Backfire: A short pop of the torch flame
followed by extinguishing of the flame or
continued burning of the gases.
• Flashback: when the torch flame moves into
or beyond the mixing chamber.
• Preheating: Heating prior to a welding or
cutting operation
 Equipment Required
• Oxygen cylinder
• Acetylene cylinder
• Pressure regulators
• Two hoses encased together
• Welding torch with tips
• Welding goggles and safety glasses
• Striker
• Check valves to prevent flashback
Acetylene Regulator
Oxygen Regulator
Typical Torch
Torch Parts
Striker
Cutting Tip
Welding and Heating Tips
Check Valves
Safety Rules for Oxy-Acetylene Workplace

• Keep the work area free of grease, oil, and

flammable materials
• Cool or quench hot metal and extinguish all
sparks before leaving. Sparks can travel up to 35
feet.
• Don’t leave torches, or hot metal where
someone will pick them up
• Never carry matches or lighters into any work
area
Pressure Gauge Failure
Cracked Acetylene Hose
Improper Storage of Tanks
Oxygen/
Acetylene
Cutting
Torch
Stored on
Unsafe
Cart
Oxygen/ Acetylene Cutting Torch Stored in
Flammable Liquids Cabinet
 Regulator Parts

Pressure regulators reduce the supply pressure, indicated by the

high pressure gauge to suitable working pressure, indicated by the
low pressure gauge. By turning the adjusting screw, proper
working pressures can be achieved.
 Personal Safety
• Shirts
– keep collar and sleeves buttoned to keep out sparks. Avoid
wearing shirts with pockets.
• Pants or Coveralls
– no cuffs and come over shoe tops
• Shoes
– leather, cover entire foot
• Gloves
– Leather, never use to pick up metal
• Safety Glasses
– worn under helmets and goggles and all times.
 Eye Protection
• Wear safety glasses at all times
• Wear welding goggles or a face shield with a
lens no. 4-6 while using torch equipment
– when in doubt start with too dark of a lens and
then switch to a lighter one.
 Color Codes
• Green = Oxygen
• Red = Acetylene
 Pressure Regulating Valves
• Each regulator has two gauges mounted on a
single manifold. One indicates cylinder
pressure and the other indicates working
pressure for the torch.
• Each regulator has an adjusting screw or T-
screw, so pressure to the torch can be quickly
controlled by turning the screw righty-tighty to
increases pressure and left-loosey to decrease
pressure.
 Regulator Attachment
– Acetylene connectors have a V-groove left handed
thread
– Oxygen connectors have a plain surface right
handed thread
 PSI Settings
• Acetylene = 15 psi. max
– Over 15 psi. can be fatal
– Our regulators in the lab will be set at 7 psi. max.
• Oxygen = 40 psi. max
– Over 40 psi. will dilute the heat of the flame
– Our regulators in the lab will be set at 30 psi. max.
 Torch Parts
• Torch body is the part of the torch that is held
like a pencil. It contains two needle valves to
control the flow of gas
• The welding head contains a mixer, mixing
throat, and the welding tip
 Types of Flames
• Oxidizing
– Excess oxygen with no feather, makes hissing
sound. Sounds like an angry snake.
– Least used for anything
• Neutral
– Burns equal amounts of oxygen and acetylene and
has a clear edged inner cone
– Most used
 Types of Flames
• Carburizing
– Excess acetylene with an acetylene feather two to
three times the length of the inner cone
– While burning it will produce a heavy black smoke
flame
– Used some in hardsurfacing, adds carbon to metal
 Operation Safety
• 1. Before you start make sure personal safety
is followed.
• 2. Make sure you have had instruction
• 3. Release adjusting screw on regulators
before opening valves
• 4. Stand on the opposite side of the regulator
when opening a valve
• 5. Open cylinder valve slowly, oxygen first all
the way open acetylene just a quarter of a turn
 Operation Safety (II)
• 6. Do not use or compress acetylene at pressures higher
than 15 psi.
• 7. Set working pressures as desired.
– Acetylene: 10 psi for NCWHS lab
– Oxygen: 30 psi for NCWHS lab
• 8. Light acetylene first
9. Never use oil on regulators or any equipment
– If oil mixes or touches the acetylene it will combust
• 10. Do not use compressed air as a substitute for oxygen
• 11. Keep heat, flames, and sparks away from
combustibles.
• 12. Keep hoses out of sparks or spatter to prevent leaks
 Safety Lighting the Torch
• Check the torch valves to make sure they are closed
• Open the oxygen tank valve full open
• Open the acetylene tank valve ¼ turn
• Turn on the oxygen knob on the torch body
– This is located next to the acetylene knob
• Turn the acetylene gas on no more than ¼ turn
• Strike and light
• Mix oxygen into the flame with the mixing knob on the torch body.
While mixing you want to create a neutral flame. Press down on
the cutting lever also to make sure the flame does not jump.
– The mixing knob is located half-way up the torch body next to the cutting
lever
 Shutting down the unit
• Shut down the flame by turning off the acetylene knob on the
torch body.
• Close the oxygen mixing knob located half-way up the torch
body
• Shut off the tanks by closing the tank valves
• Open the acetylene to purge or bleed the line
• When both gauges read zero, close the valve
• Open the oxygen valve
• When both gauges read zero, close the valve
• Release pressure on the regulators by turning adjusting screw
left or T-screw (out). DO NOT remove the T-screw
• Coil hoses and put tools away