weldingintro

Arc Arc WeldingWelding

EquipmentEquipment

Power SwitchPower Switch

Used to turn Used to turn welder on and offwelder on and off

Range Selector SwitchRange Selector Switch Use switch to select Use switch to select

ac or dc welding ac or dc welding amperage.amperage.

High and Low rangeHigh and Low range If amperage is in If amperage is in

overlapping range use overlapping range use lower range for better lower range for better amperage control.amperage control.

Do not change Do not change position of switch position of switch while welding.while welding.

Amperage Adjustment Amperage Adjustment ControlControl

Use control to Use control to adjust amperage.adjust amperage.

Inside dial is ac Inside dial is ac low and high low and high range. range.

Outside ring is dc Outside ring is dc low and high low and high range.range.

Do not adjust when Do not adjust when circuit is closed.circuit is closed.

Cable attachments for Cable attachments for AC & DCAC & DC

Cables are Cables are attached for AC attached for AC welding.welding.

Do not walk on Do not walk on cables.cables.

Do not change to Do not change to DC welding DC welding without instructor without instructor approval.approval.

Ground ClampGround Clamp

Must be attached Must be attached to welding table or to welding table or metal to be welded metal to be welded in order to in order to complete welding complete welding circuit.circuit.

You must clean You must clean painted, dirty, or painted, dirty, or rusted metal to get rusted metal to get a good ground.a good ground.

Electrode HolderElectrode Holder

Insulated.Insulated. Holds electrodes Holds electrodes

while welding.while welding. Do not burn Do not burn

electrodes shorter electrodes shorter than 1 inch.than 1 inch.

Welding TableWelding Table

Must be made of Must be made of metal.metal.

Hang cables on Hang cables on hooks rather than hooks rather than laying on floor.laying on floor.

Position exhaust Position exhaust vent near welding vent near welding base metal.base metal.

Welding ElectrodesWelding Electrodes Standard diameter sizes Standard diameter sizes

are 3/32”, 1/8”, and 5/32”.are 3/32”, 1/8”, and 5/32”. 6013 rod is for new metal. 6013 rod is for new metal.

Attractive bead. Easy to Attractive bead. Easy to weld with.weld with.

6011 rod is for used and 6011 rod is for used and dirty metal. Deep dirty metal. Deep penetration. Most penetration. Most utilitarian rod for farm and utilitarian rod for farm and ranch use.ranch use.

7014 rod is a fast fill rod 7014 rod is a fast fill rod that produces attractive that produces attractive welds.welds.

7018 is a low hydrogen 7018 is a low hydrogen rod. Best with DCRP.rod. Best with DCRP.

Welding Helmet or Welding Helmet or ShieldShield

Used to protect Used to protect face and eyes.face and eyes.

Must have a Must have a shade10 lens, shade10 lens, minimum.minimum.

Other EquipmentOther Equipment

Chipping hammerChipping hammer Used to remove slag.Used to remove slag.

Welding gloves.Welding gloves.

Used to protect Used to protect hands.hands.

Wire brush and file.Wire brush and file.

Used to clean metal.Used to clean metal.

Tongs Tongs

Used to carry hot Used to carry hot metal.metal.

HousekeepingHousekeeping Cleaning work areasCleaning work areas Sweeping—prevent slips and fallsSweeping—prevent slips and falls Keeping designated walking areas Keeping designated walking areas

clear of debrisclear of debris Restoring equipment and tools Restoring equipment and tools

after job is completedafter job is completed

Fire PreventionFire Prevention

Discard frayed Discard frayed cords and wirescords and wires

Keep flammable Keep flammable liquids away from liquids away from heatheat

Class C fire Class C fire extinguishers for extinguishers for electrical fires with electrical fires with a 15 foot maximum a 15 foot maximum distance apartdistance apart

General ManagementGeneral Management

Safety programs—training, Safety programs—training, meetings, etc.meetings, etc.

MSDS sheetsMSDS sheets Emergency phone numbersEmergency phone numbers

SAFETY: Eye ProtectionSAFETY: Eye Protection

““An ounce of prevention is worth a An ounce of prevention is worth a pound of cure” when it comes to eye pound of cure” when it comes to eye protectionprotection

Always wear proper eye protection Always wear proper eye protection when working in the shopwhen working in the shop

A welder must be protected from A welder must be protected from harmful light radiation given off by the harmful light radiation given off by the welding processwelding process

For welding you will be using chipping For welding you will be using chipping goggles and a welding helmetgoggles and a welding helmet

Here are Here are

examples of examples of

proper eye proper eye

protectionprotection

Dress CodeDress Code

Wear properly fitted clothes.Wear properly fitted clothes. When welding, sleeves should When welding, sleeves should

be buttoned and gloves should be buttoned and gloves should be worn.be worn.

Wear boots or high top; Tightly Wear boots or high top; Tightly laced shoes.laced shoes.

Do not wear loose clothing, Do not wear loose clothing, shirt tails, and unbuttoned shirt tails, and unbuttoned sleeves around power sleeves around power equipment.equipment.

Do not wear clothes that you do Do not wear clothes that you do not want to get dirty. not want to get dirty.

Here’s a good example of a Here’s a good example of a welder wearing all the welder wearing all the proper welding protectionproper welding protection

BehaviorBehavior

Most accidents are caused by Most accidents are caused by carelessnesscarelessness

Caused by human errorCaused by human error Refrain from getting involved in poor Refrain from getting involved in poor

shop behavior:shop behavior:scufflingscuffling playing with toolsplaying with tools

trippingtripping runningrunning

pushingpushing hurrying projects hurrying projects

disobeying shop rulesdisobeying shop rules loud talkingloud talking

Welding FumesWelding Fumes

Welding fumes can be harmful to Welding fumes can be harmful to the welder causing implications the welder causing implications such as:such as: Irritation of the respiratory tractIrritation of the respiratory tract Metal fume feverMetal fume fever A condition known as siderosisA condition known as siderosis Slightly increase the risk of lung Slightly increase the risk of lung

cancercancer For these reasons, one should take For these reasons, one should take

precaution with welding fumesprecaution with welding fumes

Welding FumesWelding Fumes

Welding should be Welding should be done in a well done in a well ventilated areaventilated area

Should attempt to Should attempt to control fumes at control fumes at the sourcethe source Common waysCommon ways

Extracted benchesExtracted benches Local exhaust Local exhaust

ventilation ventilation

Common Ventilation Common Ventilation PracticesPractices

Extracted bench method Local exhaust ventilation

Examples of Welding Examples of Welding PracticesPractices

ConclusionConclusion

You have just received a crash You have just received a crash course in general and welding shop course in general and welding shop safety. Using these guidelines and safety. Using these guidelines and precautions will provide a safer, precautions will provide a safer, more efficient workplace.more efficient workplace.

Questions?????? Questions??????

Arc Welding SafetyArc Welding Safety• 1. Always weld in a 1. Always weld in a

well ventilated area. If well ventilated area. If proper ventilation is proper ventilation is not available, go not available, go outside.outside.

• 2. Always use a helmet 2. Always use a helmet or hand shield that is or hand shield that is in good condition in good condition when welding. If the when welding. If the lens is bad, cracked, lens is bad, cracked, or broken replace it or broken replace it before welding. Use at before welding. Use at least a # 10 shade least a # 10 shade lens for electric arc lens for electric arc welding.welding.

Arc Welding SafetyArc Welding Safety

3. Never look at a 3. Never look at a welding arc with the welding arc with the naked eye.naked eye.

4. Do not strike an arc 4. Do not strike an arc until you are sure until you are sure those in the vicinity those in the vicinity have protective have protective equipment or have equipment or have turned their eyes turned their eyes away from the arc.away from the arc.


5. use eye protection 5. use eye protection when chipping slag when chipping slag from a weld.from a weld.

6. Always wear 6. Always wear suitable clothing (long suitable clothing (long sleeves, gloves, heavy sleeves, gloves, heavy pants, heavy boots) to pants, heavy boots) to protect the body from protect the body from arc burns and spatter arc burns and spatter of hot metal.of hot metal.


7. Don not weld around 7. Don not weld around combustible materials.combustible materials.

8. Do not weld on 8. Do not weld on containers that may containers that may contain combustible contain combustible substances.substances.

9. Do not change 9. Do not change welding amperage welding amperage when the circuit is when the circuit is closed.closed.


10. Do not leave 10. Do not leave electrode holder on the electrode holder on the table or in contact with table or in contact with a grounded metal a grounded metal surface.surface.

11. Never leave the 11. Never leave the machine when the machine when the circuit is closed.circuit is closed.

12. Do not use the 12. Do not use the welder on or around welder on or around wet surfaces.wet surfaces.


13. Place hot 13. Place hot electrode stubs in a electrode stubs in a metal container for metal container for disposal. Never throw disposal. Never throw them on the floor.them on the floor.

14. Make sure all 14. Make sure all connections are tight connections are tight before welding.before welding.