What is Welding and Types of Welding?

● Necessary Clothing: Safety glasses, jacket, long pants, leather shoes, gloves, cotton
clothes.

● OSHA: Occupational Safety and Health Administration.

● Welding Process: A concentrated heat source melts the material in the weld area, the
molten area then solidifies to join the pieces together. Sometimes a filler material is
added to the molten pool to strengthen the weld.

● Physics of Welding: In fusion welding, a source of high-density heat energy raises the
temperature of the surfaces enough to cause localized melting; if the heat density( power
+ surface area) is too low, the heat is conducted away as fast as it is added and melting
does not occur.

● Current types of welding for manufacturing: Fusion welding, oxyfuel welding

Gas Metal Arc welding

● DCEP This Refers to the direct current that flows through the welder
● Shielding gas Gas that forms a layer that prevents flame from reacting with oxygen

Electrode extension
● Adjustments in the distance a charge in the wire

POwer settings
● Wire speed knob, A faster wire speed will require more amps to keep it from melting
● Voltage control knob The thicker the metal the more required voltage

Gun Angle
● The angle of the gun in the relation to the workpiece
● The arc force can be used to counteract the gravitational force in the molten weld pool

Travel Speed
● The arc needs to be kept right at the front of the welf pool
● Too fast and you can ever in the ability of the arc to melt the base metal which results in
poor usiton
● Too slow and the weld pool builds up and transfers heat into the deposit creating a poor
Welding safety Questions
1. What is the key to preventing accidents in a welding shop
a. -Following the rules and safety regulations
2. Whos is responsible for the welders safety
a. - The person welding
3. Describe three classifications for Burns
a. -1st degree (red but unbroken skin), 2nd degree (Blisters and break in skin,
severely damaged) 3rd degree (Tissue below the skin is damaged, charred
or white skin)
4. What emergency steps must be taken to treat burns
a. : 1st and 2nd Degree (use cold water) 3rd degree (call an ambulance if victim is
on fire smother with blanket do not use cold water)
5. 3 Light represent during welding
a. :ultraviolet Infrared and visible light

6. What type of light is most loikely to Burn skin

a. :Ultraviolet
7. What can be done to reduce reflected light
a. : Use weld curtains or Black paint
8. Eye burn that can occur in a fraction of a second
a. :Flash Burn
9. In what who ways can ultraviolet light burn the eyes
a. : Can injure the white of the eye or the retina.
10. Why is it important to seek nmedical attention for eye burns
a. :Possible loss of eyesight and risk of infection
11. What clothes should you wear in the shop
a. : 100% wool, 100% cotton. Dark colored and thick woven.
12. Ideal Work pants shirt boots and caps worn in the shop
a. :Shirt - long sleeved, pants - long enough to cover tops of boots and without cuffs,
boots - must have high tops, caps - should be thick.
13. Why shouldnt you carrty butane lighters in your poket while welding
a. :They may catch fire or explode
14. What special protective items can be worn to porovide extra protection fo a welders hand
arms and body
a. :All leather gauntlet type gloves, leather jackets, aprons, leather pants and spats
15. Why should you wear eye protection in the shop
a. :To avoid debris and light reflection and excessive exposure to arc light.
16. What injuries can occur to the ears
a. :Causes of pain and loss of hearing, burns.
17. What should you use to protec ears
a. :Headphones and earpmuffs
18. What types on information should be coverd in a resporator training progam
 a. :Proper respirator use, Maintenance schedules and respiratory selection, regular
program evaluation.
19. Name two repirators and how they work
a. :Demand respirators are atmosphere supplying respirators that admit breathing air
to the face piece only when a negative pressure is created inside the face piece by
inhalation. Positive pressure respirators are respirators in which the pressure
inside the respiratory inlet covering exceeds the ambient air pressure outside the
respirator.
20. : List the dangerous fumes while welding
a. :Paints, coating, or plating or metals.
21. Why must you clean used metal before welding
a. :Some contain lead based painting
22. Where can you use natural ventilation
a. :10,000 cubic feet or more per welder or 16 fight or higher ceilings
23. Two advantages of recycling scrap metal
a. :Good for the environment and generate revenue for the welding shop.
24. : When is forced ventilation to be used
a. :In small shops or shops with large number of welders and welding metals that
give off dangerous fumes.
25. : who must be provided with Safety Data Sheets
a. :Must be provided to anyone with the product or working in the area where the
product is in use.
26. Describe an acceptable storage area for a cylinder of fuel gas
a. :Located away from halls, stairways, and exits and away from heat, radiators,
furnaces, and welding sparks. Stored separately by 20 feet or by a wall 5 feet high
with at least ½ hour burning rate.
27. How must gas cylunders be stored
a. :Secured with chain or other device and with a valve protection clap.
28. What should you do if a leak cannot be stopped
a. :It should be moved to a vacant lot or an open area, then pressure should be
slowly released after posting warning sign.
29. why hsoulf you not store acetylene cylinders horizontally
a. :May draw acetone out of the cylinder which lowers the flame temperature and
can damage regulator or torch valve settings.

30. : What is hot work

:welding outside
31. How far should combustible materials be from welding
a. 35 feet or more.

32. When is firewatch needed

 a. When the fire alarm is pulled or an extinguisher is used
33. List four types of extinguishers and what material they are used on
a. :-Type A [solids wood, cloths, paper] Type B [oils, paint, gas] Type C[fuse box,
motors, welding machines] Type D [zinc, magnesium, titanium]
34. : Why is it important to have a planned maintenance program for tools and equipment
a. :To prevent tools from breaking or wearing out
35. : Why is it important to keep the welding area clean
a. : To prevent injury
36. What should you do if you have to leave a hot piece of metal unattended
a. :Write the word hot
37. Why must a mushroomed chisel or hammer be reground
a. : So metal chips to not fly off
38. What causes electric shock in the welding industry
a. : Contact with poorly insulated conductors
39. According to the welding checklist what are the factors necessary for a confined space
hazard
a. :-Metal enclosure, Wetness, Restricted entry ,Heavier than air gas, Welder inside
or on workpiece
40. What can happen if too much power is carried by a cable
a. : It can overheat and break the insulation
41. : Why must equipment be turned off and unplugged before working on electrical
terminals
a. : Prevent electrocution
42. : According to table 2-2 what gauge wire should would be needed for a power tool that
has a nameplate amperage of 9 and a cord of 100 feet
a. :12 gauge wire
43. : What is GFCI
a. :Ground-Fault Circuit Interpreter
44. : List safety tips for safe extension cord use
a. :Connect cord to tool into extension cord first ,unplug extension cord from
receptacle first ,Extension cords should not come in contact with sharp objects &
must be positioned appropriately
b.
45. 10 rules for portable electric tools
a. :Know the tool and ground when needed
-Do not expose to water
-Do not force a cutting tool to cut faster
-Use the right tool for the right job
-Wear eye and face protection
-Secure your work with clamps
-Disconnect from power source when not in use
-Check to see keys or wrenches are removed
-Avoid accidental starting
-Be sure accessories and bits are attached securely
 46. WHy is it important to not weld while everything is wet
a. :Risk of electrocution
47. : List two types of grinders used by welders
a. : Pedestal and portable grinders
48. : Name metal cutting machines and describe what they are used for
a. :-Shear, punches, cut-off machines, and band saws
49. -Advantages are thermal cutting include little or no post-cutting cleanup, wide variety of
metals can be cut, & the metal is not heated
50. How should you lift a heavy object
a. :Distribute the weight evenly without lifting with your back
51. What should you inspect on a ladder
a. :look for loose or damaged steps, rungs, rails, braces
52. 5 ladder safety rules
:-Tie ladder securely in place
-Do not exceed the manufacturers recommend maximum weight limit
-Climb & descend the ladder cautiously
- Never use ladders around live electrical wires
-Wear well-fitted shoes or boots

Shielding Gas
Argon
Helium
Argon-Helium
CO2
Undercut: cut base metal too much