1. Arc Welding Basics SECTION OVERVIEW:
Section Overviews are provided on the introductory slides at the front of each topical area to explain the intended use for the slides included in the section.
Slide numbers are included on the Section Overview slides for easy reference when preparing for delivery of the slide content.
TEACHER NOTES:
Teacher Notes are included on the Section Overview slides as a reference tool when making class preparations.
Suggested Activities are included for teachers to use to help students gain practical experience with the welding content. However, these are designed to be supplemented by each teacher based on local program needs.
Slides have been developed to incorporate content information regarding performance standards from the American Welding Society (AWS) and the National Academic Standards for English, Science, and Math.

2. Unit Topics Topics included in this overview are: Introduction
What is Arc Welding?
Why is Welding Important?
Why Learn to Weld?
Careers in Welding
The American Welding
Society (AWS)
Welding Safety
Basic Electricity
Welding Fundamentals
Welding Certification
SECTION OVERVIEW:
This slide is meant to start generating conversation and thoughts about content to be covered in this lesson.
TEACHER NOTES:
Bulleted information on topical areas is provided to lead class discussion on areas which are to be covered in the training.

3. Objectives
Upon successful completion of this unit of study, you will be able to …
Identify definitions and terminology associated with welding
Demonstrate safe working habits in the welding environment
Name the parts and types of welds and weld joints
Interpret basic welding symbol information
Identify opportunities available to welders
SECTION OVERVIEW:
This slide is included to explain the objectives of this unit of study.
TEACHER NOTES:
Teachers could use this opportunity to give a high-level overview of the importance and application of welding in today’s society.

4. Introduction SECTION OVERVIEW:
These slides are to serve as an opener for discussions about the basics of arc welding.
TEACHER NOTES:
Slides 4-9: Slides are provided for teachers to use to help students learn about the basics of arc welding.
Slide content is designed to serve only as a framework for class discussions and should be supplemented with additional materials based on local program needs.
The American Welding Society
Contact you local chapter
Student memberships available
You do not need to be a member to attend a chapter meeting.
Find out more at

5. Arc welding is most commonly used to join two pieces of metal
What is Arc Welding?
Arc welding is most commonly used to join two pieces of metal
The welder creates an electric arc that melts the base metals and filler metal (consumable) together so that they all fuse into one solid piece of metal
Steel Pipe – Tack Welded
Final weld after several beads are made
Root Pass or “Stringer Bead”

6. Why is Welding Important?
Many things around us are welded …
Pipelines that bring fresh water
Towers that carry electricity to houses
Cars and buses that take people where they need to go

7. Welding is so HOT …. it’s COOL!
Why Learn to Weld?
Welding is so HOT …. it’s COOL!
Welding can help build a successful career so you can get the things you want in life
Skilled welders are in demand – people use things that are welded everyday!
Welding can be fun and safe
It is challenging and high-tech

8. Basic Steps of Arc Welding
Prepare the base materials: remove paint and rust
Choose the right welding process
Choose the right filler material
Assess and comply with safety requirements
Use proper welding techniques and be sure to protect the molten puddle from contaminants in the air
Inspect the weld

9. The American Welding Society
Who is the AWS?
American Welding Society
It is a non-profit organization whose membership includes:
Individuals
Students
Companies
What do they do?
Their purpose is to:
Advance the science, technology, and application of welding and allied processes including: joining, brazing, soldering, cutting, and thermal spray
Standardize classification of electrode and base material codes
Standardize process procedures
Provide welding certification

10. Careers in Welding SECTION OVERVIEW: The next few slides discuss:
The types of jobs available using welding
Why welding is important
Careers in welding
TEACHER NOTES:
Slides 10-12: Information included on these slides are intended to help students understand:
Opportunities available to skilled welders
That welding provides many opportunities for making money
Additional links for more information on careers and the demand for skilled welders:
National Association of Manufacturers:
2005 Skills Gap Report:
Keeping America Competitive:

11. Job opportunities in welding are changing …
Careers in Welding
Job opportunities in welding are changing …
Welding can be valuable as a job skill or as a full-time job
Engineering
Racing
Industrial Sales
Farm Repair and Fabrication
Production Welding
Military
Teaching
Maintenance
Robotics
Ironworker/ Skilled Trades
Auto Technician
Artist
Metal Sculpting
Owning Your Own Business
For more information on welding careers, please see the e-learning introduction

12. How Much Money Can You Make?
Recent statistics show that some welding jobs pay $25.00 per hour
- If you worked five days a week for one year, how much money would you make?
83% of people with welding jobs were offered medical benefits
- Higher than any other work sector except government
For more information on welding statistics, please log on to

13. Application Activity SECTION OVERVIEW:
The next slide is meant as a visual for a group activity.
TEACHER NOTES: (Explanation of Activity)
Arrange the participants into pairs.
Explain that this activity is meant to be an energizer activity that gets them thinking about their future.
Have participants work in teams on the computers to research career information.
Give the groups at least 60 minutes to find career-related information.
At the end of the 60 minutes, ask the students to tell how welding wages and benefits compare with other career fields.
Please Note: Other resources not mentioned on the slide which can be used as references include: the website for Ironworkers, Boilermakers, other skilled trades, local colleges, and Department of Commerce.
PLEASE NOTE: If students do not have access to the Internet, hard copies of this activity can be used along with additional supplemental career information.

14. Application Activity America's Job Bank (http://www.ajb.dni.us)
Classifieds Employment (
Yahoo! Careers (  
MONSTER.COM ( (
CareerBuilder (
Let’s explore some career possibilities in welding
Please log on to a computer
Working with a team member, research the websites to the right and explore information about welding careers
In 60 minutes, be prepared to answer the following questions:
What careers in welding interest you the most?
How can welding be high tech?
How much money can be made annually in this chosen career field?
Where can you get a job in welding and what are the basic requirements?
What are some job advancement opportunities available in the welding industry?

15. Welding Safety SECTION OVERVIEW:
The next few slides identify safety requirements when welding.
TEACHER NOTES:
Slides 15-27: Bulleted information on topical areas is provided to lead class discussion on important areas of safety in the welding environment.
Use this time to discuss OSHA (Occupational Safety & Health Administration)
OSHA -
Regulation 1910 – Occupational Safety and Health Standards for general industry
Tell the students where all the information listed on the following slides can be found.
MSDS – Quick Links: MSDS or call
See slide 20 for additional website links
See Facilitator’s Guide for more information on welding hazards such as Fumes and Gases and Electrical Shock.
For a free DVD on Welding Safely, submit the order form found in the back of the Lesson Plan Facilitator’s Guide (shipping and handling charges will apply).

16. Arc Welding Safety
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)

17. Understand and follow all warning labels found:
On welding equipment
With all consumable packaging
Within instruction manuals

18. Material Safety Data Sheets
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 Lincoln Electric consumable product
Available free online at:
front

19. MSDS outlines a product’s:
MSDS - Continued
MSDS outlines a product’s:
Identity and composition
Potential hazards
Safe use
Handling information
Manufacturer contact information
back

20. ANSI Z49.1
ANSI Z49.1: Safety in Welding, Cutting, and Allied Processes
A safety document published by the American Welding Society that covers safe practices in the welding environment
To get your free copy, go to:
E205: Arc Welding Safety
A safety document summarizing many of the hazards and safe practices for welding
Download and print your own copy at:
Free copies available from Lincoln Electric at:
Access the E-learning

21. Protect yourself and others from potential hazards including:
Arc Welding Safety
Protect yourself and others from potential hazards including:
Fumes and Gases
Electric Shock
Arc Rays
Fire and Explosion Hazards
Noise
Hot objects

22. Fumes and Gases 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

23. Do not make repairs yourself, alert your instructor immediately!
Electric Shock
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
Do not make repairs yourself, alert your instructor immediately!

24. Arc Rays Arc rays can injure eyes and burn skin
The welding arc is brighter than the sun
Precaution must be taken to protect your eyes and skin from UV radiation
Wear correct eye and body protection

25. Fire and Explosion Hazards
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

26. Loud noises can damage your hearing
Keep loud noises at a safe level by using proper hearing protection such as:
Ear plugs
Ear muffs

27. Protective Clothing 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

28. Application Activity SECTION OVERVIEW:
The next slide is meant as a visual for a group activity.
TEACHER NOTES: (Explanation of Activity)
Explain that this activity is meant to be a check and balance activity to ensure that each understands safe work practices.
Work in groups to identify possible safety hazards
Demonstrate the use of proper safety precautions by
Reading and following warnings
Using proper protective clothing
Inspecting welding areas
Other application activity ideas:
Read and explain an MSDS
Reference ‘Safety in Welding, Cutting and Allied Processes’ (ANSI Z49.1)
Reference Lincoln Electric’s ‘Arc Welding Safety’ (E205)
Read and explain a warning label on a package of electrode
Read and explain a warning label on a welding power source

29. Application Activity TIME TO PRACTICE Go out to the lab
Demonstrate the use of proper safety precautions such as:
Reading warnings
Using proper protective clothing
Equipment inspection
Keeping your head out of the fume
Proper ventilation

30. Basic Electricity and Welding
SECTION OVERVIEW:
The next slides are meant to explain basic electricity and its relationship to arc welding.
TEACHER NOTES:
Slides 30-32: Bulleted information on topical area is provided to lead class discussion on the importance of electricity in arc welding processes.

31. The Arc Welding Circuit
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

32. Basic Electricity
DC -
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
Polarity
DC- (Direct Current Electrode Negative)
DC+ (Direct Current Electrode Positive)
AC (Alternating Current)
DC+ AC

33. Math Terms and Welding SECTION OVERVIEW:
The next few slides are intended to help students connect welding with math applications needed in the work world.
TEACHER NOTES:
Slide 33-34: This slide contains information to help clarify how several math terms apply to welding.

34. Math Terms in Welding
Believe it or not, a lot of math is used in welding
IPM Travel Speed = Inches per Minute Travel Speed
The speed the electrode moves along the base material
IPM Wire Feed Speed= Inches per Minute Wire Feed Speed
The speed at which the wire is fed during wire welding
Lbs/hr = Pounds per Hour
Electrode deposition rate
CFH= Cubic Feet per Hour
Shielding gas flow rate (wire welding)
PSI= Pounds per Square Inch
Tensile strength of a material and the pressure in gas cylinders
L = Leg
Fillet size measurement
% = percent
Shielding gas mixture composition

35. Metals SECTION OVERVIEW:
The next slides are intended to help students understand the specifics about technical aspects associated with welding. Included is information on:
Common metals that can be welded
Sheet metal gauges
TEACHER NOTES:
Slides 35-37: These slides contain information about common types of metals, their weldability and gauge sizes. This information can help students visualize the concepts discussed on the slides.

36. Can All Metals Be Welded?
Most metals can be welded, but not all
The three most common weldable metals include:
Mild Steel - inexpensive and strong
Stainless Steel – does not rust
Aluminum – does not rust and is light weight
Mild steel
Aluminum
Stainless Steel

37. 16 gauge = .051” 14 gauge = .064” 12 gauge = .081” 10 gauge = .102”
Material thickness is sometimes measured by gauge from 36 (.004 in) to 3 (.2391 in)
For example, steel gauge and measurement in inches:
16 gauge = .051” gauge = .064” gauge = .081” gauge = .102”
PLEASE NOTE: As the gauge number gets smaller … the material thickness gets larger.

38. Types of Joints SECTION OVERVIEW:
The next slide is intended to help students learn about the various types of joints that can be used with welding. Information includes:
Types of joints
TEACHER NOTES:
Slide 38-39: Examples of various types of joints are provided to help students visualize the concepts discussed on this slide.

39. Types of Joints
There are 5 types of joints …

40. Parts of a Weld SECTION OVERVIEW:
The next slides are intended to help students develop an understanding of the parts of a weld and of fillet weld inspection
TEACHER NOTES:
Slides 41-43: Examples of various types of welds are provided to help students visualize the concepts discussed.
Common terms and definitions applied to fillet and groove welds:
Fillet Weld: Triangular cross section joining two surfaces approximately at right angles to each other in a lap joint, T-joint, or corner joint
Groove Weld: A weld made in the groove between work pieces.
Fillet Weld Leg: Distance from the joint root to toe of fillet weld
Weld Toe: Junction of weld face and base metal
Weld Face: Exposed surface on side where welding was done
Weld Root: Point at which the back of the weld intersects the base metal surface
Actual Throat: Shortest distance between weld root and face of fillet weld
Notice the term ‘convex’ in Slide 43. Define for the class and give examples.
To order free posters on the parts of a weld, types of joints, positions and welding symbols go to (Winter 2006)

41. Parts of a Weld
Heat Affected Zone
Joint and Weld

42. Fillet and Groove Welds
Groove and fillet welds can be made on many types of joints

43. Fillet Weld Inspection
Fillet welds should:
Have a flat to slightly convex face
Be uniform in appearance
Have equal leg size
Have good wash-in into base materials
This is an example of a good fillet weld:

44. Welding Symbols SECTION OVERVIEW:
The next slides are intended to help students learn about welding symbols
TEACHER NOTES:
Slides 44-46: These slides show some examples of actual welding symbols which can help students more easily grasp the concepts discussed.
For more information on welding symbols, see “How to Read Shop Drawings” available for purchase from the James F. Lincoln Foundation (
To order free posters on the parts of a weld, types of joints, positions and welding symbols go to (Winter 2006)

45. What are Welding Symbols?
Welding symbols give the welder specific instructions about the weld including:
Placement
Size
Length
Process
Any other special notes
Welding symbols are
Universally used
Governed by the AWS
Found on engineering drawings
“How to Read Shop Drawings” available at

46. Welding symbols contain information about the weld to be made
S – leg dimension of the weld
Triangle – the weld is to be made on the arrow side of this joint
Tail – any additional information required (i.e. position the weld is to be made)
Arrow - the joint the welding symbol applies to

47. Welding Positions SECTION OVERVIEW:
This next slide is intended to help students learn about welding positions.
TEACHER NOTES:
Slides 47-48: Show examples of welding positions to help students more easily grasp the concepts discussed in this section.
To order free posters on the parts of a weld, types of joints, positions and welding symbols go to )

48. What are Welding Positions?
There are various positions that a weld can be made in:

49. Welder Responsibilities
SECTION OVERVIEW:
The next few slides reference information extracted from the ‘Guide for the Training and Qualification of Welding Personnel, Entry Level Welder’ (AWS EG 2.0) booklet to help students understand about the responsibilities of a welder.
TEACHER NOTES:
Slides 49-55: These slides include bulleted information on topical areas to lead class discussion on the importance of each area when conducting the welding processes.
‘Guide for the Training and Qualification of Welding Personnel, Entry Level Welder’ (AWS EG 2.0) book available through the AWS. (
For more information on Lincoln Electric's Welding Educator’s Workshop see the Technical Training Guide (ED122):

50. What are the Responsibilities of a Welder?
Welders have many areas of important responsibilities
These relate to:
Arc Welding Safety
Knowledge – Content
Attitude – Reactions
Skills – Performance
Work Habits – Daily Functions
Always keep safety in mind when welding

51. A welder MUST always follow safe work practices:
Arc Welding Safety
A welder MUST always follow safe work practices:
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)

52. Welding can teach you about….
Knowledge - Content
Welding can teach you about….
Science when applying metallurgy, chemistry, electricity, etc.
Math when calculating angles, joint design, and weld size
English when communicating and interpreting drawings, codes, and procedures
Technical areas when performing the actual welding applications
How much science and math went into the development of this bike?

53. Attitude
The best welders demonstrate a can-do attitude when performing welding processes
This means being able to…
Work as a team member
Communicate ideas to others
Listen to opinions of others
Promote a positive attitude
Provide solutions to problems
Take pride in workmanship
These welders work together to inspect a weld.

54. Skills/Performance
A welder must demonstrate technical skills when performing welding processes
A welder must know how to:
Use hand tools and materials, to operate equipment in a safe, accurate, and consistent manner
Acquire and evaluate information needed for problem solving
Complete quality work
Maintain equipment
There is no room for poor workmanship in NASCAR

55. Work Habits/Daily Functions
A welder must practice good working habits when performing welding processes
This means being able to …
Follow detailed verbal and written instructions
Maintain workspace, equipment, and tool cleanliness
Correctly fill out, maintain and submit time cards, work assignment cards, and other records as required
Follow safe working practices
Agriculture teachers brush up on their welding skills at Lincoln Electric’s Welding Educator’s Workshop

56. Welding Certification
SECTION OVERVIEW:
The next slides discuss the basics of the certification process.
TEACHER NOTES:
Slide : Bulleted information on topical area is provided to lead class discussion on certification possibilities.

57. Welding Certification
What is a welding certification?
Welding certifications are used to test a welder’s knowledge and welding skill
Certifications are available for many different processes, materials, and positions.
Who certifies welders?
Certification programs are offered by many different types of organizations:
Companies
Skilled Trades
Military
Ship Builders
Pipelines
The American Welding Society

58. Welding Certification
How can you become certified?
Certification testing is available at testing facilities all over the United States
The AWS offers many certifications including: welders, welding inspectors, and welding educators
What is the value of a welding certification?
A welding certification proves that you have passed a test and are qualified for the job
As an AWS certified welder your name is kept in a national database which is used to notify you of jobs open in your area
It is a source of accomplishment and pride

59. English, Math, and Science Connection
SECTION OVERVIEW:
The next slides discuss how the content covered in the welding unit is applicable to English, Math, and Science classes.
TEACHER NOTES:
Slides 59-61: These slides contain information regarding how this welding unit of study relates to the National Academic Standards.

60. English, Math, and Science Connection
Many of the same concepts you learn in other classes are practiced in welding. In what other classes might you study the following terms?
75/25 – gas mixture
Volts
Amps
Degree/hr – cooling rate
In/min
Angles/degrees
Metallurgy
Fillet size
Current
Tension
Compression
Tensile strength
Yield
Blueprints
Depth/width ratio
Preheat temperature
Cubic feet per hour

61. National Academic Standards Crosswalk
The unit just completed has covered parts of academic content listed in the National Academic Standards as follows:
NM-PROB.CONN.PK-12.3: Recognizes and applies mathematics in contexts outside of mathematics.
NLA-STANDARD 1: Uses the general skills and strategies of the writing process.
NLA-STANDARD 7: Uses reading skills and strategies to understand and interpret a variety of informational texts.
NS-PHYSICAL SCIENCE: (Experiences) interactions of energy and matter.