LESSON one

Topic: Introduction To Welding

Instructor: DEJENE LEGESSE
 CONTENTS TO BE DISCUSSED
LESSON ONE
Introduction
Definition of welding
Welding terminology
Welding symbol
Welding joints
Welding positions
Types of welding
LESSON TWO
Shielded Metal Arc Welding (SMAW)
LESSON THREE
Oxyacetylene Welding (OAW)
 Cont…
LESSON FOUR
Gas Metal Arc Welding(GMAW)
LESSON FIVE
Gas Shielded Tungsten Welding (GTAW)
LESSON SIX
Welding Defect
LESSON SEVEN
 Welding Safety
 Introduction

What is welding?
Welding is the melting, flowing together, and
freezing of metals under controlled conditions.
Parts are joined together by Fusion. Fusion is
brought about by a combination of heat and
pressure between parts being joined.
In normal welding processes very high
temperatures and little or no pressure is used.
Welding is an effective method of making
permanent joints between two or more metal
parts.
A Weldor is the person doing the welding.
A Welder is the machine doing the welding.
WELDING TERMINOLOGY

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 Generalized Welding Symbol

FAR SIDE DETAILS Field weld symbol

Weld Geometry

Electrode D L1-L2 Weld all-around for

pipes, etc.
Material D L1-L2

ARROW SIDE DETAILS D = Weld Depth (usually equal to plate thickness)

L1 = Weld Length
L2 = Distance between centers for stitched welds

The Field Weld Symbol is a guide for installation. Shipyards

normally do not use it, except in modular construction.
Example Welding Symbol

Geometry symbol for V-groove

One-sided welds are max 80% efficient

Two sided are 100% efficient
1/2

1/2

1/2” 1/2”
 Cont…

OTHER SIDE

ARROW SIDE Work

Fillet Weld (Arrow Side Only) Fillet Weld (Both sides)

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Weld Symbols (Butt Joints)

Backing
Weld Symbol (Fillet Joints)
Weld Symbol (Corner Joints)
 Welding Positions

There are four types of welding positions, which are

given as:
Flat or down hand position
Horizontal position
Vertical position
Overhead position
 Types of Joints
(A) BUTT JOINT, (B) CORNER JOINT, (C) LAP JOINT, (D)
TEE JOINT, and (E) EDGE JOINT
 TYPES OF WELD
I. Groove Welds

(a) Square groove weld, one side; (b) single bevel groove
weld; (c) single V-groove weld; (d) single U-groove weld; (e)
single J-groove weld; (f) double V-groove weld for thicker
sections (dashed lines show original part edges)
 II. Fillet Welds

(a) Inside single fillet corner joint; (b) outside single

fillet corner joint; (c) double fillet lap joint; (d)
double fillet tee joint (dashed lines show the
original part edges)
 III. PLUG WELD and SLOT WELD
(A) PLUG WELD and (B) SLOT WELD
 IV. Spot Weld and Seam Weld

Fused section between surfaces of two sheets or

plates: (a) spot weld and (b) seam weld
• Used for lap joints
• Closely associated with resistance welding
 Types of Welding

Fusion Welding Pressure Welding

Homogeneous Heterogeneous Friction Welding

Gas Welding Brazing Soldering

Electroslag MIG
High Energy Beam TIG

Electric Arc Shielded Metal Arc – “Stick” 19

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 Electric Arc Welding
The heat for fusion is supplied by an electric arc

Arc is formed between electrode and work this melts

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and fuses the joint edges
Types of Electric Arc Welding

Manual Metal Arc (MMA)

Metal Arc Gas Shielded (MAGS) MIG
Tungsten Arc Gas Shielded (TAGS) TIG
Submerged Arc Welding (SAW)

Gas Welding
Oxyacetyline Welding

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 END OF LESSON
ONE

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 LESSON TWO

Shielded Metal Arc Welding

(SMAW)

June, 2015
 SHIELDED METAL ARC WELDING
It is typically a manual welding process where
the heat source is an electric arc which is
formed between a consumable electrode and
the base material.
The electrode is covered by a coating, which is
extruded on the surface of the electrode.
During welding, the electrode coating
decomposes and melts, providing the protective
atmosphere around the weld area and forming
a protective slag over the weld pool.
Cont….
 Cont….
The arc is struck between the tip of the
electrode and the workpiece.
The arc is moved over the work at the
appropriate arc length and travel speed, melting
and fusing a portion of the base metal and
continuously adding filler metal.
Electrode types and sizes, (with predetermined
coating compositions) are selected to
correspond to the required strength levels of
base metal, the types of welding power supplies
utilized and depth of penetration and amount of
weld metal fill required.
Cont…
 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 28
 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 Equipment Set Up
1. Turn power supply on 4. Adjust output
2. Connect work clamp a. Polarity
3. Select electrode b. Amperage
a. Type 6. Insert electrode into electrode holder
b. Diameter

30
 SMAW Process Variables
Settings on the machine
Polarity : AC, DC+, DC-
Amperage Output
Operator Controlled
Variables
Work Angle
Travel Angle
Arc Length
Travel Speed A straight AC machine
will not have a polarity
switch like this
31
AC/DC machine
 Striking an Arc
To begin the SMAW Process, you must first strike an
arc. This can be done using one of the following
techniques:
Scratch start – scratch the electrode on the base metal
like a match
Tap Start – tap the rod against the base metal

32
 Work Angle
The work angle is the
angle between the
electrode and the work
as depicted on the left
Work angles can vary
90° depending on the
position the weld is
being made in

33
 Travel Angle
Also commonly called
Lead Angle
The travel (lead) angle is
the angle between the
20-30° electrode and the plane
perpendicular to the weld
axis

34
 Arc Length
After striking the arc, maintain a 1/8” distance between the
electrode and the workpiece
If the arc length becomes too short, the electrode will get stuck to
the workpiece or ‘short out’
If the arc length becomes too long; spatter, undercut, and porosity
can occur

Arc Length =
1/8”
35
 Travel Speed
The travel speed is the
speed at which the End of Weld

electrode moves along the

base material while
welding
Too fast of a travel speed
results in a ropey or convex
weld
Too slow of a travel speed
results in a wide weld with
an excessive metal deposit
The travel speed impacts the shape
of the bead.

36
 ELECTRODES
In general, all electrodes are classified into five main groups:
 Mild steel
 High-carbon steel
 Special alloy steel
 Cast iron
 Nonferrous
 The widest range of arc welding is done with electrodes in the mild steel
group.
 Electrodes are manufactured for use in specific positions and for many
different types of metal.
 They also are specially designed to use with ac or dc welding machines.
Some manufacturer’s electrodes work identically on either ac or dc,
while others are best suited for flat-position welding.
 Another type is made primarily for vertical and overhead welding, and
some can be used in any position.
 As you can see, electrode selection depends on many variables.
 Electrodes
SMAW uses a consumable electrode that contains a
flux coating
The flux produces a protective gas around the weld
CO (Carbon Monoxide)
H2 (Hydrogen)
Removes impurities from the molten metal
Forms slag to protect weld as it cools
 Electrode Care
Electrodes must be kept dry
Dampness will introduce hydrogen into the weld causing
cracking or brittleness
Damp electrodes may cause the flux to “blow away”
Questionable electrodes should be baked at 250° F for
several hours.
Our electrodes are stored in a dry oven
Electrode Identification
 Electrode Characteristics
AWS Current
Class Covering Requirements Position Characteristics

EXX 10 Cellulose DCEP All Deep Penetration,

Sodium With Ripples

EXX 11 Cellulose AC, DCEP All Deep Penetration,

Potassium Flat Decking With Ripples

EXX22 Rutile DCEN, AC Flat, Horiz. Fillet Deep Penetration,

Sodium With Ripples

EXX 24 Rutile AC, DCEP, DCEN Flat, Horiz. Fillet High Deposition
50% Iron Shallow Penetration
Powder
EXX 27 Mineral AC,DCEP, DCEN Flat, Horiz. Fillet High Deposition
50% Iron Shallow Penetration
Powder
 Electrode Characteristics continued
AWS Current
Class Covering Requirements Position Characteristics

EXX 12 Rutile DCEN, AC All Mild to Medium Penetration

Sodium

EXX 13 Rutile AC, DCEP, DCEN All Mild Penetration

Sodium

EXX 14 Rutile AC, DCEN All Medium Penetration

30% Iron
Powder
EXX 18 Low-Hydrogen DCEP, AC All Medium Penetration
30% Iron
Powder
EXX 28 Low-Hydrogen AC, DCEP Flat, Horiz. Fillet High Deposition
50% Iron
Powder
 E6013 Electrodes
E= Electrode
60= 60,000 psi Tensile Strength
Tensile Strength= Maximum pull stress in pounds per square
inch that a specimen will withstand.
1= All positions
3= High titania potassium
E6011 Electrodes
E= Electrode
60= 60,000 psi Tensile Strength
1= All positions
1= High-Cellulose, potassium flux composition
• These electrodes are good for low carbon Steel
 Polarity
Polarity is the direction of the current flow in a
circuit, as shown in figure 7-9.
With ac welding machines, polarity is not a
problem.
When using dc welding machines, you can weld
with either straight polarity or reverse polarity.
Cont…
 Cont…
In straight polarity, the electrode is negative and the
workpiece positive; the electrons flow from the
electrode to the workpiece.
In reverse polarity, the electrode is positive and the
work-piece negative; the electrons flow from the
workpiece to the electrode.
On some of the older machines, polarity is changed
by switching cables. On many of the newer
machines, the polarity can be changed by turning a
switch on the machine.
 Cont…
Polarity affects the amount of heat going into the
base metal.
By changing polarity, you can direct the amount of
heat to where it is needed.
When you use straight polarity, the majority of the
heat is directed toward the workpiece.
When you use reverse polarity, the heat is
concentrated on the electrode.
 Cont…
In some welding situations, it is desirable to have more
heat on the workpiece because of its size and the need for
more heat to melt the base metal than the electrode;
therefore, when making large heavy deposits, you should
use STRAIGHT POLARITY.
In general, straight polarity is used for all mild steel, bare,
or lightly coated electrodes. With these types of electrodes,
the majority of heat is developed at the positive side of the
current, the workpiece.
Reverse polarity is used in the welding of nonferrous
metals, such as aluminum, bronze, Monel, and nickel.
Reverse polarity is also used with some types of electrodes
for making vertical and overhead welds.
 AC vs. DC
• DC • AC
Heat Concentrated at Work Heat Concentrated at
piece Electrode

Forceful, Digging Arc Lower Penetration

Medium to Deep Penetration Increased Deposition Rates

(used for welding thin
metal)
 Approximate Amperage Settings
Approximate Electrode Amperage Settings

Fast Freeze Fill Freeze Fast Fill Low Hydrogen

E6010 - E6011 E6013 - E7014 E7024 - E7028 E7018

Diameter of Current Setting Current Setting Current Setting Current Setting

Electrode
Inches(Millimeters) Amperes Amperes Amperes Amperes

3/32 in (2.4 mm) 40 - 90 75 - 105 85 - 155 70 - 140

1/8 in (3.2 mm) 75 - 130 100 - 165 100 - 175 90 - 185
5/32 in (4.0 mm) 80 - 160 135 - 225 160 - 270 140 - 230
3/16 in (4.8 mm) 110 - 225 185 - 280 220 - 330 210 - 300
7/32 in (5.6 mm) 200 - 260 235 - 340 270 - 410 230 - 380
1/4 in (6.4 mm) 220 - 325 260 - 425 315 - 520 290 - 440
 Lesson three
Part one

Oxyacetylene Welding
(OAW)
 Oxyacetylene Welding (OAW)
The oxyacetylene welding process uses a
combination of oxygen and acetylene gas to
provide a high temperature flame.
OAW is a manual process in which the welder must
personally control the the torch movement and
filler rod application
The term oxyfuel gas welding outfit refers to all the
equipment needed to weld.
Cylinders contain oxygen and acetylene gas at
extremely high pressure.
Typical Oxyacetylene Welding (OAW) Station
 Oxygen Cylinders
Oxygen is stored within cylinders of various sizes
and pressures ranging from 2000- 2640 PSI. (Pounds Per
square inch)

Oxygen cylinders are forged from solid armor plate

steel. No part of the cylinder may be less than 1/4”
thick.
 Cylinders are then tested to over 3,300 PSI using a
(NDE) hydrostatic pressure test.
Oxygen Cylinders
 Cylinders are regularly re-
tested using hydrostatic
(NDE) while in service
 Cylinders are regularly
chemically cleaned and
annealed to relieve “jobsite”
stresses created by handling .
 Cylinder Transportation
Never transport cylinders without the safety caps in
place
Never transport with the regulators in place
Never allow bottles to stand freely.
Always chain them to a secure cart or some other
object that cannot be toppled easily.
 Oxygen Cylinders

 Oxygen cylinders incorporate a thin metal “pressure safety disk”

made from stainless steel and are designed to rupture prior to the
cylinder becoming damaged by pressure.
 The cylinder valve should always be handled carefully
 Pressure Regulators for Cylinders

Reduce high storage cylinder pressure to lower working

pressure.
Most regulators have a gauge for cylinder pressure and
working pressure.
Pressure Regulators for Cylinders
Regulators are shut off
when the adjusting screw
is turn out completely.
Regulators maintain a
constant torch pressure
although cylinder
pressure may vary
Regulator diaphragms are
made of stainless steel
Pressure Regulators Gauges Using a
“Bourdon” movement
Gas entering the gauge fills a
Bourdon tube
As pressure in the
semicircular end increases it
causes the free end of the
tube to move outward.
 This movement is
transmitted through to a
curved rack which engages a
pinion gear on the pointer
shaft ultimately showing
pressure.
Regulator Hoses
Hoses are fabricated from
rubber
Oxygen hoses are green in
color and have right hand
thread.
Acetylene hoses are red in
color with left hand thread.
Left hand threads can be
identified by a grove in the
body of the nut and it may
have “ACET” stamped on it
Check Valves &Flashback Arrestors
Check valves allow gas
flow in one direction
only
Flashback arrestors are
designed to eliminate
the possibility of an
explosion at the
cylinder.
Combination Check/
Flashback Valves can be
placed at the torch or
regulator.
 Acetylene Gas
Virtually all the acetylene distributed for welding
and cutting use is created by allowing calcium
carbide (a man made product) to react with water.
 The nice thing about the calcium carbide method
of producing acetylene is that it can be done on
almost any scale desired.
Placed in tightly-sealed cans, calcium carbide keeps
indefinitely.
Before acetylene in cylinders became available in
almost every community of appreciable size
produced their own gas from calcium carbide.
 Acetylene Cylinders
 Acetylene is stored in cylinders specially designed
for this purpose only.
 Acetylene is extremely unstable in its pure form at
pressure above 15 PSI (Pounds per Square Inch)
 Acetone is also present within the cylinder to
stabilize the acetylene.
 Acetylene cylinders should always be stored in the
upright position to prevent the acetone form
escaping thus causing the acetylene to become
unstable.
Acetylene Cylinders

Cylinders are filled with a

very porous substance
“monolithic filler” to
help prevent large
pockets of pure
acetylene form forming
Cylinders have safety
(Fuse) plugs in the top
and bottom designed to
melt at 212° F (100 °C)
Acetylene Valves
Acetylene cylinder shut
off valves should only be
opened 1/4 to 1/2 turn
This will allow the cylinder
to be closed quickly in
case of fire.
Cylinder valve wrenches
should be left in place on
cylinders that do not have
a hand wheel.
 Oxygen and Acetylene Regulator Pressure
Settings
Regulator pressure may vary with different torch styles
and tip sizes.
PSI (pounds per square inch) is sometimes shown as PSIG (pounds
per square inch -gauge)

Common gauge settings for cutting

 1/4” material Oxy 30-35psi Acet 3-9 psi
 1/2” material Oxy 55-85psi Acet 6-12 psi
 1” material Oxy 110-160psi Acet 7-15 psi
Check the torch manufactures data for optimum
pressure settings
Typical torch styles
 A small welding torch, with throttle
valves located at the front end of the
handle.
 Ideally suited to sheet metal welding.
 Can be fitted with cutting attachment
in place of the welding head shown.
 Welding torches of this general design
are by far the most widely used.
 They will handle any oxyacetylene
welding job, can be fitted with
multiflame (Rosebud) heads for
heating applications, and
accommodate cutting attachments
that will cut steel 6 in. thick.
 A full-size oxygen cutting torch which
has all valves located in its rear body.
 Another style of cutting torch, with
oxygen valves located at the front end
of its handle.
 Typical startup procedures
 Verify that equipment visually appears safe IE: Hose
condition, visibility of gauges
 Clean torch orifices with a “tip cleaners” (a small
wire gauge file set used to clean slag and dirt form
the torch tip)
 Crack (or open) cylinder valves slightly allowing
pressure to enter the regulators slowly
 Opening the cylinder valve quickly will “Slam” the
regulator and will cause failure.
 Typical startup procedures
Never stand directly in the path of a regulator when
opening the cylinder
Check for leaks using by listening for “Hissing” or by
using a soapy “Bubble” solution
Adjust the regulators to the correct operating
pressure
Slightly open and close the Oxygen and Acetylene
valves at the torch head to purge any atmosphere
from the system.
Always use a flint and steel spark lighter to light the
oxygen acetylene flame.
 Flame Settings
There are three distinct types of oxy-acetylene
flames, usually termed:
– Neutral
– Carburizing (or “excess acetylene”)
– Oxidizing (or “excess oxygen” )
The type of flame produced depends upon the ratio
of oxygen to acetylene in the gas mixture which
leaves the torch tip.
Pure Acetylene and Carburizing Flame profiles
Neutral and Oxidizing Flame Profiles
 FLAME DEFINITION
The neutral flame (Fig. 4-1) is produced when the ratio of
oxygen to acetylene, in the mixture leaving the torch, is
almost exactly one-to-one. It’s termed ”neutral” because it
will usually have no chemical effect on the metal being
welded. It will not oxidize the weld metal; it will not cause
an increase in the carbon content of the weld metal.
The excess acetylene flame (Fig. 4-2), as its name implies,
is created when the proportion of acetylene in the mixture
is higher than that required to produce the neutral flame.
Used on steel, it will cause an increase in the carbon
content of the weld metal.
The oxidizing flame (Fig. 4-3) results from burning a
mixture which contains more oxygen than required for a
neutral flame. It will oxidize or ”burn” some of the metal
being welded.
 Lesson three
Part two

Oxyacetylene Welding
(OAW)
Oxy-Fuel Cutting
 Cutting Equipment versus Welding Equipment
Oxy-Fuel gas cutting
equipment is used throughout
the metal-working world for
cutting steel and ferrous (iron-
based) metals.
The equipment is basically the
same for both oxy-fuel gas
cutting and oxy-fuel gas
welding, except for the torch.
The cutting torch is a unique
and invaluable tool that
enables the operator to cut
almost any thickness of steel
to the required size and
shape.
Oxy-Fuel Cutting
Oxy-fuel gas cutting is also
referred to as flame cutting.
Flame cutting is a process of
cutting steel by removing
material to form a slot,
called the kerf.
The metal is actually
removed from the kerf by
burning it away.
Flame cutting is one of the
fastest and most efficient
methods for cutting thick
metal.
Elements for Burning - Fuel
 To understand how metal
can be cut quickly with a
flame, you must first
understand how burning
takes place
 Three essential elements
are needed for burning:
Fuel, Oxygen, and Heat.
 Fuel can be any material
that will chemically
combine with oxygen.
 In this case, the steel to be
cut is the fuel.
Elements for Burning - Oxygen
Second, a large quantity of
pure oxygen is needed to
combine with the fuel.
The more oxygen present,
and the greater the
oxygen’s force, the faster
burning will take place.
Therefore, flame cutting
requires a jet stream of
pure oxygen directed onto
the steel.
 Elements for Burning - Heat
 Third, heat is needed to raise the
temperature of the steel until it reaches its
ignition temperature.
 Ignition temperature is the temperature at
which the material will burn when oxygen is
present.
 The ignition or kindling temperature of steel
is 1500 degrees Fahrenheit.
 At this temperature, steel turns cherry red.
 The stream of oxygen is directed onto the
hot metal.
 The steel burns rapidly, and a slot is cut
through the entire piece.
 The oxygen and hot steel are actually
combining to form a chemical reaction called
oxidation.
 Flame Cutting – How it works?
The Oxy-Fuel cutting process
is accomplished by bringing
the base metal to a molten
state, then introducing a
high-pressure stream of
cutting oxygen.
This will ignite and burn the
metal as well as carry away
the slag or oxidized residue.
 Importance of Torch Cutting
 More people use the oxy-fuel cutting
torch than any other welding process.
 The cutting torch is used by workers in
virtually all areas including
manufacturing, maintenance,
automotive repair, railroad, farming,
and more.
 Most workers know how to light the
torch and make a cut, but their cuts are
very poor quality and often unsafe.
 A good oxy-fuel cut should not only be
straight and square, but it should
require little or no post-cut cleanup.
 Excessive post-cutting cleanup results
in extra cost, which is an expense that
cannot be justified.
 Getting Started- Inspect the Equipment
1. Inspect the cone end, coupling nut, and torch head for
dirt, dust, oil, grease, or damaged parts. Dirt and dust can
be removed with a clean cloth.
• CAUTION: If oil, grease or damaged parts are detected,
DO NOT USE! Report it to the instructor immediately!
 Inspect the “O”Rings
2. Inspect the cutting
attachment cone end
for missing or
damaged “O” rings.
Damaged or missing
“O” rings can allow
gases to mix and will
cause backfires or
backflash.
Inspect the Cutting Tips

3. Inspect the torch head.

The tapered seating
surfaces must be in good
condition.
• If dents, burns or burned
seats are present, the
seat must be resurfaced.
• If the torch is used with a
bad seat, backfire or
backflash may occur.
 Setting up the Cutting Head
4. Connect the cutting HAND TIGHT ONLY
attachment to the
welding torch handle
and tighten the
coupling nut, using
hand pressure only.
• Wrench tightening may
damage “O” rings and
create a faulty seal.
Tip Selection
5. Select the required size
and type of cutting tip.
Attaching the Cutting Tip
6. Insert the tip in the
cutting attachment head
and tighten securely with an
open-end wrench.
Wrench Tight Connecting
Nut
 LESSON four

Gas Metal Arc Welding

(GMAW)
 Gas Metal Arc Welding (GMAW)
 GMAW stands for Gas Metal Arc Welding
 A solid metal wire is fed through a welding gun and becomes
the filler material
 Shielding gas is used to protect the molten puddle from the
atmosphere which results in a weld without slag.
 It is a semi-automatic or automatic arc welding process in which
a continuous and consumable wire electrode and a shielding
gas are delivered to the weld through a welding gun.

93
 GMAW COMPONENT

What is the function

of each part?
94
GMAW System Parts
A. Hand wheel
B. Flow meter
C. Wire spool
D. Wire
E. Feed roll tension
F. Voltage meter
G. Wire speed meter
H. Wire speed adjustment
I. Voltage adjustment
J. Power switch
K. Gun cable
L. Gun
M. Ground clamp
N. Ground cable
O. Feed rolls
P. Wire guide
Q. Wire overrun
R. Safety nut

95
 Flow meter
What is the purpose of the flow meter?
 Two types of flow meters are
available.
 One piece: the gas flow rate is
regulated by using a fixed orifice
and changing the pressure to
change the flow rate.
 Two piece: the gas flow rate is
adjusted by using a constant
pressure regulator and changing
the flow rate with an adjustable
orifice (needle valve).
96
Welding Gun
Function is to deliver the
shielding gas, wire and
welding current to the weld
pool.
MIG guns are rated on
amperage capacity.
 The reason is heat.
 >400 amps are water cooled.
Welding wire is delivered to Gun end cutaway
the gun by the liner. 1. Cable
 Liner must sized to the welding wire. 2. Insulation ring
 Small liner = excessive friction which may cause 3. Gas diffuser
the wire to seize.
4. Contact tube
 Large liner = wire can buckle and spring
forward causes erratic wire feed. 5. Wire
 Liner must be correct length. 6. Nozzle
97
 Welding Gun--cont.
Contact tube Nozzle
 Sliding electrical connection.
 Must match the diameter of the wire
 Must be replaced frequently

The nozzle directs the shielding Contact tube

gas towards the weld pool.

98
 Operating Variables That Affect Weld
Formation
Factors that affect operation of arc and weld
deposit
Sound welding of good appearance results when
variables in balance
Necessary to become familiar with all variables

22 - 99
 Power Supply
GMAW and FCAW both use a constant voltage
power supply.
 Many different types are available.
 Industrial rate are usually 100% duty cycle.
 Non industrial power supplies have sloping duty cycle.
 May have a built in heat sensitive overload switch.

Install power supply so that the cooling air through

the machine is not restricted.

100
 Selecting Power Supply
Seven factors to consider when selecting a GMAW or
FCAW power supply.
1 Type of metal
2 Metal thickness range
3 Type of metal transfer
4 Wire diameter range
5 Primary power available
6 Capacity of power source
7 Control and adjustments

101
 Direct Current Electrode Positive (DCEP)
 Generally used for gas metal arc welding
– Provides maximum heat input into work allowing relatively deep
penetration to take place
– Assists in removal of oxides from plate
– Low current values produce globular transfer of metal from electrode
 On carbon steel shielding gas must contain minimum of 80% argon

22 - 102
 Direct Current Electrode Negative (DCEN)
 Limited use in welding of thin gauge materials
 Greatest amount of heat occurs at electrode tip
 Wire meltoff rate great deal faster than DCEP
 Penetration also less than with DCEP
 Arc not stable at end of filler wire
– Corrected by use of shielding gas mixture of 5% oxygen added to argon
– Meltoff rate reduced so benefit cancelled

22 - 103
 Alternating Current
Seldom used in gas metal arc welding
Arc unstable because of current reversal
Combination of both DCEN and DCEP polarity, rate
of metal transfer and depth of penetration falls
between those polarities
Found some use for welding of aluminum

22 - 104
 Shielding Gas
 Argon and helium first used for gas metal arc
Continue to be basic gases
 Argon used more than helium on ferrous metals to keep spatter at
minimum
Also heavier than air so good weld coverage
 Oxygen or carbon dioxide added to pure gases to improve arc
stability, minimize undercut, reduce porosity, and improve
appearance of weld.
 Helium added to argon to increase penetration
 Hydrogen and nitrogen used for only limited number of special
applications.
 Carbon dioxide has following advantages:
– Low cost
– High density, resulting in low flow rates
– Less burn-back problems because of its shorter arc characteristics
105
 Specific Metal Recommendations
 Aluminum alloys: argon
 Magnesium and aluminum alloys: 75 percent helium, 25 percent
argon
 Stainless steels: argon plus oxygen
 Magnesium: argon
 Deoxidized copper: 75 percent helium, 25 percent argon preferred
 Low alloy steel: argon, plus 2 percent oxygen
 Mild steel: 15 percent argon, 25 percent carbon dioxide (dip
transfer); 100 percent CO2 may also be used with deoxidized wire
 Nickel, Monel®, and Inconel®: argon
 Titanium: argon
 Silicon bronze: argon
 Aluminum bronze: argon
106
 Wire Feeding systems
Function is to deliver the
welding wire at a constant
rate to the gun.
Three systems
Push
Pull
Push--pull
Two types
Constant speed
Voltage sensing
Two types of construction
Internal
External

107
 Wire Drive Systems
 The drive system is responsible for pulling the wire from the
spool and then pushing the wire down the cable.

 The wire drive systems consisted of

one or more pair of feed rolls and
wire guides.
 The guides must be the proper size
and adjusted close to the feed rolls
and aligned with gap between the
rolls.

108
 Feed Rolls
For a GMAW system to work correctly, the feed rolls
must be the correct type and size.
The feed roll tension must also be set correctly.

V Groove U Groove
Knurled V groove Cogged U groove

109
 Consumables—Shielding Gases
Carbon dioxide
• Requires special valve
• Must use washer between valve and flow
meter.
Argon
• Same valve as helium
Mixture
• Same valve as argon

110
 Consumables—Welding wire
Solid (Copper clad)

Flux core

Stainless steel

Hard surfacing

Aluminum
What three wire diameters
are most popular?

111
 Mode of molten metal transfer
The GMAW process provides four different metal
transfer methods.
Short circuiting
Spray
Globular
Pulse spray

112
 Short Circuiting Transfer
When the gun trigger is activated, the wire starts to move
toward the metal.

1. When the
wire
5. The wire touches the
touches the 2. The high metal it
metal and the 4. As the wire current flow shorts out.
process continues to 3. The current melts the end
continues move, the arc pinches off the of the wire
restarts. droplet and the arc and a droplet
stops. is formed.

Process is recognizable by its sharp buzzing or crackling

sound 113
Most common method
 Spray Transfer
Requires high current density.
The current density of the spray
process causes the wire to melt
into small droplets (less than the
diameter of the wire).
The arc forces propels the droplets
to the metal.
What are the characteristics of the
spray transfer method?
Would the process work better for
thin metal or thick metal?
Is the spray transfer method
recommended for all welding
positions?
114
 Globular Transfer
 Low current density results erratic arc
and globules of metal larger than the
diameter of the wire.
 Minimum penetration.
 Excessive spatter
 Use is limited to submerged arc
welding.

115
 Pulse Spray Transfer
 In the pulse spray transfer the current alternates from the
desired welding current to a background current.
 The background current just maintains the arc.
 The peak current, time of peak current, background
current and time of background current are all adjustable.

A = Peak Current
B = Background Current
C = Peak Time
D = Pulses per Second

116
 Stickout
An important function of all GMAW processes is the
stickout.
Stickout is the distance from the end of the contact
tube to the weld surface.

117
 LESSON five
Gas Tungsten arc Welding
(GTAW)
 Introduction
The Gas Tungsten Arc Welding (GTAW) process is
sometimes referred to as a TIG
TIG is short for tungsten inert gas
The inert gas provides the needed arc characteristics
and protects the molten weld pool
GTA welding can be used for nearly all types and
thicknesses of metal
GTA welding is fluxless, slagless, and smokeless
Welders have fine control of the welding process
Some GTA welds make the critical root pass
GTA used when appearance is important
Setup of GTA equipment affects weld quality
Charts give correct settings
 GTA Welding Equipment
 GTA welding torches are water- or air-cooled
 Water-cooled GTA welding torch is more efficient
 Water-cooled torch has three hoses connecting it to the welding
machine
 Nozzle directs the shielding gas directly on the welding zone
 Flowmeter regulates the rate of gas flow
 Types of Welding Current
 DCEN concentrates about 2/3 of its welding heat on the work
– Max penetration
– High Freq. – start only
 DCEP concentrates about 1/3 of its welding heat on the work
– Max cleaning action
– 2/3 of heat at tungsten – primarily used for balling tungsten for
aluminium welding
– High Freq. – start only
 AC concentrates its heat at 50/50
– Sign wave provides for DCRP (cleaning action) and DCSP
(penetration action)
– Square wave technology allows for adjusting the cleaning or
penetration cycle.
– High Freq. is on Continuous so there is equal firing of both sides of
sign wave.
– DC Component will take place if there is no High Freq.
Power Source Basics
 Tungsten
Tungsten has the following properties:
High tensile strength
Hardness
High melting temperature
High boiling temperature
Good electrical conductivity
Tungsten is the best choice for a non consumable
electrode
High melting temperature
Good electrical conductivity
As the tungsten electrode becomes hot the arc between
the electrode and the work stabilizes
But a clean and correctly ground tungsten is needed
Because of the intense heat some erosion of the
electrode will occur
 Cont…
Ways to limit erosion:
– Good mechanical and electrical contact
– Use as low a current as possible
– Use a water-cooled torch
– Use as large a tungsten electrode as possible
– Use DCEN current
– Use as short an electrode extension as possible
– Use the proper shape electrode
– Use an alloyed tungsten electrode
 Types of Tungsten Electrodes
• Pure tungsten is an excellent nonconsumable
electrode
• Pure tungsten can be improved by adding:
– Cerium
– Lanthanum
– Thorium
– Zirconium
 Cont…

Tungsten Electrode Types and Identification.

 Shaping the Tungsten
To obtain the desired end shape:
– Grinding (for MS and SS)
– Breaking (not recommended due to cost)
– Re melting the end (Aluminium welding)
– Using chemical compound (doesn’t work that well)
Often used to clean a contaminated tungsten or to
point the end
Should have a fine, hard stone
– A coarse grinding stone will result in more tungsten
breakage
Should be used for grinding tungsten only
– Metal particles will quickly break free when the arc is
started, causing contamination
Figure 15-8 Correct way of holding a tungsten when grinding. Courtesy of Larry Jeffus.
 Breaking and Remelting
 Tungsten is hard but brittle
– If struck sharply, it will break without bending
 Holding against a sharp corner and hitting results in a square
break
 After breaking squarely, melt back the end

Chemical Cleaning and Pointing

 Tungsten can be cleaned and pointed using one of several
compounds
 Heated by shorting it against the work
 Dipped in the compound
 When the tungsten is removed, cooled, and cleaned, the end will
be tapered to a fine point
 The chemical compound will dissolve the tungsten, allowing the
contamination to fall free
 Pointing and Remelting
Tapered tungsten with a balled end is made by first
grinding or chemically pointing
The ball should be made large enough so that the
color of the end stays dull red and bright red
Increase ball size by applying more current
Surface tension pulls the molten tungsten up onto
the tapered end

Figure Melting the tungsten end shape.

 TIG Shielding Gases
Argon Helium
 Good arc starting  Faster travel speeds
 Good cleaning action  Increased penetration
 Good arc stability  Difficult arc starting
 Focused arc cone  Less cleaning action
 Lower arc voltages  Less low amp stability
 10-30 CFH flow rates  Flared arc cone
 Higher arc voltages
 Higher flow rates (2x)
 Higher cost than argon

132
 TIG Shielding Gases
Argon/Helium Mixtures
 Improved travel speeds over pure argon

 Improved penetration over pure argon

 Cleaning properties closer to pure argon

 Improved arc starting over pure helium

 Improved arc stability over pure helium

 Arc cone shape more focused than pure helium

 Arc voltages between pure argon and pure helium

 Higher flow rates than pure argon

 Costs higher than pure argon 133

 Welding Techniques
Torch Angle
As close to perpendicular as possible
May be angled 0-15 degrees from perpendicular for
better visibility
As the gas flows out it forms a protective zone
around the weld
Too much tilt distorts protective shielding gas zone.
Velocity of shielding gas affects protective zone
Low-pressure area develops behind the cup when
velocity increases
Sharper angle and higher flow rate increases
contamination
 Filler Rod Manipulation
Filler rod must be kept inside the protective zone
If filler rod is removed from the gas protection, it
oxidizes rapidly
Oxide is added to the molten weld pool
When a weld is temporarily stopped, the shielding
gas must be kept flowing
If the rod tip becomes oxidized, if should be cut off
before restarting
The rod should enter the shielding gas as close to
the base metal as possible
An angle less than 15 degrees prevents air from
being pulled in the welding zone
 Tungsten Contamination
Most frequent problem is tungsten contamination
Tungsten becomes contaminated if it touches:
– Molten weld pool
– Filler metal
Surface tension pulls the contamination up onto the
hot tungsten
Extreme heat causes some of the metal to vaporize and
form a large oxide layer
Contamination caused by the tungsten touching the
molten pool or filler metal forms a weak weld
The weld and tungsten must be cleaned before any
more welding can be done
Tiny tungsten particles will show up if the weld is x-
rayed
Contamination can be knocked off quickly by flipping
the torch head
This procedure should never be used with heavy
contamination or in the field
 Current Setting
Amperage on the machine's control is the same at
the arc when:
– Power to the machine is exactly correct

– Lead length is very short

– All cable connections are perfect

– Arc length is exactly right

– Remote current control is in the full on position

 Advantages
 Welds more metals and metal alloys
than any other process

 High quality and precision

 Pin point control

 Aesthetic weld beads

 No sparks or spatter

 No flux or slag

 No smoke or fumes
138
Disadvantages
 Lower filler metal deposition rates

 Good hand-eye coordination a

required skill

 Brighter UV rays than other

processes

 Slower travel speeds than other

processes

 Equipment costs tend to be higher

than other processes
139
LESSON SIX

Welding
Defect
 Defect
 A flaw or flaws that by nature or accumulated effect render a part or
product unable to meet minimum applicable acceptance standards
or specifications. The term designates rejectability.
 Misalignment (hi-lo)  Inclusions  Base Metal
 Undercut  Slag Discontinuities
 Wagontracks  Lamellar tearing
 Underfill
 Tungsten  Laminations and
 Concavity or Convexity  Spatter Delaminations
 Excessive reinforcement  Arc Craters
 Laps and Seams
 Improper reinforcement  Cracks
 Longitudinal  Porosity
 Overlap  Transverse  Uniformly Scattered
 Burn-through  Crater  Cluster
 Throat
 Incomplete or Insufficient  Toe
 Linear
Penetration  Root  Piping
 Incomplete Fusion  Underbead and  Heat-affected zone
Heat-affected zone
 Surface irregularity  Hot microstructure alteration
– Overlap  Cold or delayed  Base Plate laminations
 Arc Strikes  Size or dimensions
 Welding Troubleshooting
• 1. Porosity
2. Excessive Spatter
3. Incomplete Fusion
4. Lack of Penetration
5. Excessive Penetration
6. Burn-Through
7. Waviness of Bead
[Link]
 Misalignment (hi-lo)
• Definition: Amount a joint is out
of alignment at the root

• Cause: Carelessness. Also due to joining different

thicknesses (transition thickness)
• Prevention: Workmanship. Transition angles not to exceed
2.5 to 1.
• Repair: Grinding. Careful on surface finish and direction of
grind marks. Inside of Pipe /Tube difficult.
 Undercut
• Definition: A groove cut at the
toe of the weld and left unfilled.
• Cause: High amperage, electrode
angle, long arc length, rust
• Prevention: Set machine on scrap metal. Clean metal
before welding.
• Repair: Weld with smaller electrode, sometimes must be
low hydrogen with preheat. Sometimes must gouge first.
 Undercut
(cont......)

Undercut typically has an allowable limit.

Different codes and standards vary greatly in
the allowable amount.
Plate - the lesser of 1/32” or 5% (typ.)
 Insufficient Fill

• Definition: The weld surface is below the adjacent surfaces

of the base metal

• Cause: Improper welding techniques

• Prevention: Apply proper welding techniques for the weld

type and position. Use stripper beads before the cover
• pass.
Repair: Simply weld to fill. May require preparation by
grinding.
 Insufficient Fill on the Root Side
(suckback)

• Definition: The weld surface is below the adjacent surfaces

of the base metal at the weld root.
• Cause: Typically improper joint preparation or excessive
weld pool heat.
• Prevention: Correct cause. (see next slide)

• Repair: Backweld to fill. May requireremoval of weld

section by grinding for access to the joint root.
 Cause for Insufficient Fill at the Root

Some liquids, like water or molten steel, try to cover as much surface area of whatever they are
in contact with as possible.

Welding a root pass too wide can also cause the bead to sag (overhead position).
 Removing a root pass by grinding

1. Recreate the groove geometry as closely as possible.

2. Use a saw or die grinder and 1/16 - 1/8” cut off wheel to recreate root opening. Remember
repairs are sometimes required to be made with a smaller electrode.
3. Open the groove angle. Be careful to leave the proper root face dimension.
4. Feather the start and stop to blend smoothly into and out of the existing weld.
 Excessive Concavity or Convexity

• Definition: Concavity or convexity of a fillet weld which

exceeds the specified allowable limits

• Cause: Amperage and travel speed

• Prevention: Observe proper parameters and techniques.

• Repair: Grind off or weld on. Must blend smoothly into the
base metal.
Concavity
Convexity
 Reinforcement
The amount of a groove weld which extends beyond the surface of the plate

• Excessive Face Reinforcement

• Insufficient
• Improper
contour

Root Reinforcement
 Excessive Reinforcement
• Definition: Specifically defined by the standard. Typically,
Reinforcement should be flush to 1/16”(pipe) or flush to
1/8” (plate or structural shapes).
• Cause: Travel speed too slow, amperage too low

• Prevention: Set amperage and travel speed on scrap plate.

• Repair: Remove excessive reinforcement and feather the

weld toes to a smooth transition to the base plate.
 Insufficient Reinforcement
• Definition: Specifically defined by the standard. Typically,
Underfill may be up to 5% of metal thickness not to exceed
1/32” as long as the thickness is made up in the opposite
reinforcement. Not applied to fillet welds.
• Cause: On root reinforcement - Too little filler metal will
cause thinning of the filler metal. In OH position, too hot or
too wide will cause drooping of the open root puddle.
• Prevention: Use proper welding technique. Use backing or
consumable inserts. Use back weld or backing.
• Repair: Possibly simply increase the face reinforcement. If
backwelding is not possible, must remove and reweld.
 Improper Weld Contour
• Definition: When the weld exhibits less than a 1350
transition angle at the weld toe. 1350

• Cause: Poor welding technique

• Prevention: Use proper techniques. A weave or whip

motion can often eliminate the problem.
• Repair: The weld face must be feathered into the base
plate.
 Overlap

• Definition: When the face of the weld extends beyond the

toe of the weld
• Cause: Improper welding technique. Typically, electrode
angles and travel speed.
• Prevention: Overlap is a contour problem. Proper welding
technique will prevent this problem.
• Repair: Overlap must be removed to blend smoothly into
the base metal. Be careful of deep grind marks that run
transverse to the load. Also be careful of fusion
discontinuities hidden by grinding. Use NDT to be sure.
 Overlap
Overlap is measured with a
square edge such as a 6” rule. No
amount of overlap is typically
allowed.
 Burn-through (non-standard)
• Definition: When an undesirable open hole has been
completely melted through the base metal. The hole may
or may not be left open.
• Cause: Excessive heat input.

• Prevention: Reduce heat input by increasing travel speed,

use of a heat sink, or by reducing welding parameters.
• Repair: Will be defined by standards. Filling may suffice.
Otherwise, removal and rewelding may be required. Some
standards may require special filler metal and/or PWHT.
 Incomplete or Insufficient Penetration

• Definition: When the weld metal does not extend to the

required depth into the joint root
• Cause: Low amperage, low preheat, tight root opening, fast
travel speed, short arc length.
• Prevention: Correct the contributing factor(s).

• Repair: Back gouge and back weld or remove and reweld.

 Incomplete Fusion

• Definition: Where weld metal does not form a cohesive

bond with the base metal.
• Cause: Low amperage, steep electrode angles, fast travel
speed, short arc gap, lack of preheat, electrode too small,
unclean base metal, arc off seam.
• Prevention: Eliminate the potential causes.

• Repair: remove and reweld, being careful to completely

remove the defective area. This is sometimes extremely
difficult to find.
 Spatter

• Definition: Small particles of weld metal expelled from the

welding operation which adhere to the base metal surface.
• Cause: Long arc length, severe electrode angles, high
amperages.
• Prevention: Correct the cause. Base metal can be protected
with coverings or hi-temp paints.
• Repair: Remove by grinding or sanding. Sometimes must be
tested as if it were a weld.
 Arc Craters

• Definition: A depression left at the termination of the weld

where the weld pool is left unfilled.
• Cause: Improper weld termination techniques

• Prevention:

• Repair: If no cracks exist, simply fill in the crater. Generally

welding from beyond the crater back into the crater.
LESSON seven

welding
SAFETY
 Health Hazards…Gases & Fumes
Welding “Smoke” is a mixture of very fine particles called
fumes and gases
Welding “Smoke” contains fumes and gases including…
Chromium, nickel, arsenic, asbestos, manganese, silica,
beryllium, cadmium, nitrogen oxides, fluorine compounds,
carbon monoxide, cobalt, copper, lead and zinc
Generally, gases and fumes come from…
Base material & filler material
Coatings & paints
Shielding gases & chemical reactions
Process & consumables used
Contaminants in the air
 Health Hazards
It is difficult to list all the health effects of welding
exposures because the fumes may contain so many
different substances that are known to be harmful
The individual components of welding “smoke” can
affect just about any part of the body, including the
lungs, heart, kidneys, & central nervous system
Exposure to welding “smoke” may have…
Short-term effects…
– Effects happen at or very soon after exposure
Long-term effects
– Effects may happen after repeated overexposures or an
extended time after the exposure
 Short-term exposures
 Exposure to zinc, magnesium, copper and copper oxide can cause
metal fume fever
 Symptoms of metal fume fevere may occur 4 to 12 hours after
exposure
 Symptoms include…
 Chills, thirst, fever, muscle ache, chest soreness, coughing,
wheezing, fatigue, nausea, and metallic taste in mouth.
 Welding “smoke” can irritate the eyes, nose, chest and respiratory
tract
 Welding “smoke” can cause coughing, wheezing, shortness of
breath, and bronchitis.
 Welding “smoke” can cause loss of appetite, vomiting, cramps,
and slow digestion.
 Ultraviolet radiation can react with oxygen and nitrogen to form
ozone and nitrogen [Link] gases are deadly at high
concentrations and can also cause irritation of nose and throat and
cause serious lung disease
 Arc welding should never be performed within 200 feet of
degreasing equipment or solvents
 Long-term exposures
 Studies of welders, flame cutters, and burners have
shown that welders have an increased risk of lung
cancer…and…possibly cancer of the larnyx and urinary
tract
 Remember… welding “smoke” can include cancer
causing agents such as…cadmium, nickel, beryllium,
chromium, and arsenic
 Welders may experience a variety of chronic respiratory
problems, including… Bronchitis, asthma, pneumonia,
emphysema, pneumoconiosis, decreased lung capacity,
silicosis, and siderosis
 Other health problems…
 Heart disease, skin diseases, hearing loss, chronic
gastritis, gastroduodentis, and ulcers of the stomach
and small intestine
 Reproductive risks
 Electrical Hazards
 Even though welding generally uses low voltage, there is still a
danger of electric shock
 Wet work areas, Cramped work spaces
 Falls, fractures and other accidents can result from electrical
exposure
 Even small shock can cause brain damage
 Death can occur from large shocks
 Always use dry gloves
 Always wear rubber soled shoes
 Always use insulating layers
 Protect yourself from surfaces that conduct electricity
 When working on electrically powered machinery, make sure
the frame is grounded
 Keep insulation on all welding equipment and components dry
and in good condition
 Don’t change electrodes with bare hands, wet gloves or while
standing on wet or ungrounded surfaces
 Fire and Explosion Hazards
Intense heat and sparks can cause fires or explosions if
in the vicinity of combustible or flammable materials
Welding and cutting should only be performed in areas
free of combustible materials such as trash, wood,
paper, textiles, plastics, chemicals, and flammable
dusts, liquids and gases
 Never weld or cut on containers that have held a flammable or
combustible material unless the container is thoroughly cleaned
or filled with an inert gas
 A fire inspection should be performed prior to leaving a work
area and for at least 30 minutes after the operation is
completed
 Fire extinguishers should be nearby, of proper size, type and
number for the hazards involved
 Welding Hazards in Confined Space
A work area with limited access, little or no airflow,
not intended for continuous occupation
– May also have dangerous atmospheres, hazardous
configurations, or other hazards
All employees working in or around confined space
must be trained
Never weld or cut in explosive, flammable,
combustible or other dangerous environments
Always use all necessary Personal Protective
Equipment (PPE), including, harness and lanyard,
respiratory protection, eye protection, etc.
Never work in confined space without a trained
attendant
 Cont…
 Always leave gas cylinders and welding power
sources outside the confined space…
 No worker should work in an area with less than
19.5% or more than 23.5% oxygen content
 Never ventilate with oxygen
 Use continuous mechanical ventilation and proper
respiratory protection
 All pipes, ducts, power lines, etc. that are not
necessary for the work should be
disconnected/locked out/tagged out
 Compressed Gas Hazards
Gas welding and cutting use a fuel gas and oxygen
which are stored in high pressure cylinders
Most fuel gases are explosive
Pure oxygen will increase the flammability of any
combustible/flammable material.
 All cylinders should have caps or regulators
 Pressure regulators must be designed for gas in use
 Check all equipment and components prior to use
 Cylinders must be stored upright and secured
 Oxygen and fuel gas cylinders must be stored
separately
 Be aware of flashbacks and backfires??
 Close cylinder valves when work is completed or left
unattended during breaks, etc.
 Personal Protective Equipment (PPE)
 PPE must be used in conjunction with engineering
controls and safe work practices
 Use of one does not eliminate the need for the other
 Eye protection should be used in all welding
operations
– Wear face shields or helmets and goggles or safety
glasses
 Use appropriate filters on eye protection
 Filter Lens Shade Numbers
SMAW – 1/16 - 5/32 = #10
Gas SAW - 1/16 - 5/32 = #11 (nonferrous)
Gas SAW – 1/16 – 5/32 = #12 (ferrous)
SMAW – 3/16 – ¼ - = #12
5/16 & 3/8 electrodes = #14
Atomic Hydrogen Welding = #10 - #14
Carbon Arc Welding CAW = #14
 Cont…
Soldering = #2
Torch Brazing = #3 or #4
Light cutting up to 1 inch = #3 or #4
Medium cutting 1 inch to 6 inches = #4 or #5
Heavy cutting over 6 inches = #4 or #6
Light gas welding up to 1/8” = #4 or #5
Medium gas welding 1/8” to ½ “ = #5 or #6
Heavy Gas Welding over ½ “ = #6 or #8
 Protective Clothing
Fire resistant gauntlet gloves
Headcap
High top hard toed shoes
Leather apron
Faceshield
Flame retardant clothing
Safety Glasses
Safety helmet
Ear plugs and/or muffs should be worn during noisy
operations such as air arcing or grinding.
Must be fitted, cleaned, stored and maintained in
accordance to regulation and manufacturers specs
NIOSH recommends respirators whenever a carcinogen
is present
 The Well Dressed Welder
Personal Protective
Leather welding gloves Equipment
Face and head protection
Leather, cotton or wool clothes
No pockets or cuffs
Close-toed, rubber soled boots
Long pants and sleeves
 Eye and Face Protection
• Helmet-Shade 10
• Cover/Safety glasses-ANSI Z87.1 compliant
• Face Shield
 Safety Rules
Secure work
Avoid electrical
shock
Protect others
Never weld in a
damp area
Never wear
synthetic fiber
clothing
Protect welding
cables