1. History of Welding
Chapter 1

2. Overview Welding is joining two pieces of metal by:
Heating to temperature high enough to cause softening or melting
With or without application of pressure
With or without use of filler metal
Melting point same as metals being joined or melting point below metals but about 800ºF

3. Overview New methods, applications and systems
Tremendous progress in short time
Usually best method to use when fastening metal
© David H. Wells/The Image Works

4. History of Metalworking
Began when people found they could shape rocks by chipping them with other rocks
Copper probably first metal to be worked
Ductile (easily hammered, bent or drawn)
In Egypt as early as 4000 B.C. and USA before 2000 B.C.
Welding began more than 3000 years ago
Hot or cold metals hammered to obtain forge weld
Forged metals, bronze and iron mentioned in Old Testament

5. History of Metalworking
Bronze developed between 3000 and 2000 B.C.
Iron became known to Europe about 1000 B.C.
Philistines had four iron furnaces about 1300 B.C.
Produced swords, chisels, daggers, and spearheads
Egyptians began making iron tools during period of 900 to 850 B.C.
Replaced bronze as metal used in manufacture of utensils, armor and other applications after 800 B.C.

6. History of Metalworking
Famous Damascus swords and daggers made in Syria about 1300 B.C.
Sought because of their strength and toughness
Made by forge-welding iron bars of different degrees of hardness, drawing them down, and repeating process many times
Working of metals followed one another in great ancient civilizations
Copper, bronze, silver, gold, and iron

7. History of Metalworking
Time of Roman Empire
Iron use common in Europe, Near East and Far East
Chinese developed ability to make steel from wrought iron in 589 A.D.
Belgians responsible for progress with steel in Europe
Japan manufactured steel by repeated welding and forging and controlling amount of carbon by use of fluxes
Produced famous Samurai sword

8. History of Metalworking
Blast furnace developed for melting iron about 1000 to 1200 A.D.
Fourteenth and fifteenth centuries saw great improvements in design of blast furnaces
First cast iron cannon produced in early 1600s
Industrial Revolution in the middle of the eighteenth century brought many improvements

9. History of Metalworking
Present factory system of mass production introduced
American, Eli Whitney, developed idea of interchanging parts in manufacture of arms
Working of dyes and molds became commonplace by beginning of nineteenth century
Henry Ford involved in developing assembly line method for manufacturing automobiles early in twentieth century

10. Early Developments in Welding
Edmund Davy discovered acetylene at beginning of nineteenth century
Sir Humphrey Davy discovered the electric arc in 1801
Concerned with use of arc for illumination
Demonstrated possible to maintain high voltage arc for varying periods of time by 1809
Workable electrical generating devices invented and developed on practical basis by 1850
These inventions were forerunner of present arc welding process.

11. History of Fusion Welding
First documented instance done by Auguste de Meritens in 1881
Welded lead battery plates together with carbon electrode
Two of Auguste’s pupils, N. Benardos and S. Olszewski, continued work and issued patent for welding process using carbon electrodes and electric power source four years later
Primary goal was repair welding

12. Bare Metal Electrode Welding
Introduced in 1888 by N. G. Slavianoff (Russian)
Discovery first recognized in western Europe in 1892
C. L. Coffin was pioneer of welding industry in United States
1889 received patent on equipment and process for flash-butt welding

13. Bare Metal Electrode Welding
1890 received additional patents for spot welding
1892 received patent for bare metal electrode arc welding process
Without knowledge of Slavianoff’s work

14. History of Metalworking
Foresche and Picard developed first commercial oxyacetylene welding torch at turn of the 20th century
Electric arc welding method used in US until about 1920
Handicapped because of welds produced by these electrodes not as strong as metal being welded
Welding arc very unstable

15. History of Metalworking
In 1907 Kjellberg (Swedish engineer) received patent covering electrode-coating process
Coating thin and acted only as stabilizer of arc
Produced welds little better than bare electrodes
In 1912 Kjellberg received another patent for electrode with heavier coating made of asbestos with binder of sodium silicate
In 1908, Benardos patented electroslag process of welding thick plates in one pass

16. History of Metalworking
Technology of welding progressed slowly until World War I
Demands of war called for improved methods of fabrication
End of war, welding widely accepted
Research on coated electrodes through 1920s resulted in electrode coatings and improved core wire

17. Multipass Welds
Pass 1
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Ability to make multipass welds such as this one, on plate and pipe, led to growth of industry. Welds are sound and have uniform appearance.
Pass 2
Pass 3

18. History of Metalworking
Stick welding process
Advanced rapidly due to electrode coatings and improved core wire
Now called shielded metal arc welding (SMAW)
X-ray development
Possible to examine internal soundness of welded joints

19. Shipbuilding
5,171 vessels constructed to American Bureau of Shipping standard
Through 1945
During Maritime Commission wartime shipbuilding program
Welding was replacing riveting as main method of assembly

20. Development of Modern Welding
Design of welding machines changed very little during postwar period
Done with d.c. current from batteries
Use of a.c. welding machines occurred in late 1920 and increased in the early 1930s
First high frequency a.c. industrial machine introduced in 1936 by Miller Electric Manufacturing Company
High rate of metal deposition and absence of arc blow

21. Inert Gas Welding World War II spurred development
Possible to produce welds of high purity and critical application
Patent issued in 1930 to Hobart and Devers for use of electric arc within inert gas atmosphere
Not well received because high cost of argon and helium and lack of suitable torch equipment

22. GTAW Welding Tungsten electrode replace magnesium procedure
Patent issue in 1942
Linde Company developed gas tungsten arc welding (GTAW)
Also called tungsten inert gas (TIG) process or HELIARC
Perfected water-cooled torch capable of high amperage

23. Tungsten Inert Gas (TIG) Process
An aluminum weld made using the TIG process. The welding of aluminum is no longer a problem and can be done with the same ease as that of steel.
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24. GTAW Welding First done with rotating d.c. welding machines
Later a.c. units developed
In 1950s
Selenium rectifier type d.c. welding machines
a.c.-d.c. rectifier welding machines with built-in high frequency for GTAW welding became available
Miller Electric Manufacturing Company developed Miller controlled-wave a.c. welder for critical welds on aircraft and missiles

25. Development of Modern Welding
Use of aluminum and magnesium increased
Development of GTAW welding
Desirable characteristics of reduced weight and resistance to corrosion
Thicker materials in construction, which required preheating using GTAW welding
U.S. patent issued in 1948 for gas metal arc welding (GMAW) process
Superseded earlier terms of metal inert gas (MIG) and metal active gas (MAG)

26. GMAW Process Concentrates high heat at a focal point Produces
Small heat-affected zone
Narrow bead width
Deep penetration
Faster welding speed
Now used in all industries
This and similar processes
are responsible for over 70 percent of welds being performed today.
St Louis Car. Co.
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27. FCAW Process
Tubular wire filled with flux: outside acts as electrical conducting sheath and provides bulk of weld bead; core contains scavengers and deoxidizers
Some flux cored electrodes generate sufficient gas shielding; referred to as self-shielding (FCAW-S)
Other flux cored electrodes require an external shielding gas (FCAW-G)
Flux cored wire welding high-deposition process is fast and economical
Slag that retards cooling rate and supports molten weld pool allowing certain electrodes to weld in all positions

28. Development of Modern Welding
Rapid changes occurred in 1980s and continuing today
Exotic multiple gas mixes
State-of-art electrodes
Onboard computers
Robotic welding
Hybrid process
Methods developing that may change way welds made in future

29. Processes and Applications Involving Use of the Electric Arc
Arc spot welding
Atomic-hydrogen welding
Electrogas
Plasma arc welding
Stud welding
Submerged arc welding
Underwater arc welding

30. Other Specialized Processes Include
Cold welding
Electron beam welding
Explosive welding
Force welding
Friction welding
Friction stir welding
Laser welding
Oxyhydrogen welding
Thermit welding
Ultrasonic welding
Welding of plastics

31. Industry Demand Over 90 welding processes defined
Force new and improved developments in machines, gases, torches, electrodes, procedures, and technology
Constant research for new metals done by shipbuilding, space and nuclear industries
Spurs research in welding

32. Provide guidance and standards relating to the welding industry.
Welding Associations
American National Standards Institute (ANSI)
American Petroleum Institute (API)
American Society of Mechanical Engineers (ASME)
American Welding Society (AWS)
American Bureau of Shipping (ABS)
Provide guidance and standards relating to the welding industry.

33. Welding as an Occupation
Can be certified by AWS, ASME and API
Tests difficult and require many hours of practice
Key positions in major industries
Important to economic welfare of country
Gender friendly
Done in every civilized country in the world
Offer prestige and security
Chances for advancement excellent

34. Industrial Welding Applications
More than 90 different welding processes
Divided into three major types
Arc
Gas
Resistance
Number of other types used to lesser extent
Induction, forge, thermit, flow, and brazing

35. Resistance Welding
Includes spot welding, seam welding, flash welding, projection welding, and other similar processes performed on machines
Operators usually taught on job
Semiskilled workers do not need specific hands-on-welding skills

36. Arc and Gas Welding Focus of this text Combine art and science
Welders have almost complete control of the process
Must know properties of metals to weld; which weld process to use; and how to plan, measure, and fabricate

37. Welding Positions Overhead Vertical As well as flat and vertical
Miller Electric Mfg. Co.
Vertical
As well as flat and vertical
Miller Electric Mfg. Co.
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38. Qualifications and Personal Characteristics
Welders certified for ability to do work and work is inspected
Required to pass periodic qualification tests
Certifications issued according to kind and gauge of metal and specific welding process
Can hold several different certifications simultaneously

39. Example of Magnetic-particle Testing in Building
Weld testing and inspection give proof of the soundness of welds.
Circlesafe Aerosol/Circle Systems, Inc.
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40. Basic Tasks Gas weld Electric arc welding
Attaching proper tip and adjusting welding regulators for proper volume and gas pressures
Electric arc welding
Regulate welding machine for proper welding current, select proper electrode size and type, and right shielding gas
Need steady hand and have good visualization skills

41. Master Welder Job Examples
Creating Art!
Enrique Vega
Welds in these tanks must meet X-ray requirements and pass a dye penetrant test. Tanks are often lined with a very thin layer of pure silver.
AP Photo/U.S. Department of Energy, The Monroe Evening News
Copyright © The McGraw-Hill Companies, Inc. Permission required for reproduction or display.

42. Master Welder Master craftsperson Able to weld all steels and alloys
Plus nickel, aluminum, tantalum, titanium, zirconium, and their alloys and claddings
Welds of highest quality
Welds meet requirement of job
Delicate welding of silver and gold
Heavy pressure vessels requiring 4-inch plate

43. Welding Occupations Requiring a High School Education
Welding operator
Welding fitter
Combination welder
Master welder
Welding supervisor
Welding analyst
Inspector
Welding foreman
Welding superintendent
Equipment sales
Sales demonstrator
Sales troubleshooter
Welding instructor
Robotics welder operator
Job or fabrication shop owner

44. Welding Occupations Requiring a High School Education
Welding engineer (metallurgical)
Welding development
engineer
Welding research
Welding engineer
Technical editor
Welding professor
Certified welding inspector (AWS/CWI)
Corporation executive
Owner of welding business
Sales engineer

45. Safety and Working Conditions
Indoors or outdoors
Noisy
Hearing protection needed
Awkward positions
Spacious surroundings
or cramped quarters
High off ground in scaffolds with safety harness
© Vicki Silbert/PhotoEdit

46. Job Hazards Fire danger Burns (including “sunburn” from electric arcs)
Noxious fumes from materials vaporized at high temperatures
Eyestrain
Welders flash
Electric shock
Hazards can be minimized or eliminated by use of proper protective clothing and equipment.

47. Ways to Stay Current
Read trade journals, service manuals, textbooks, and trade catalogs.
Join associations such as the American Welding Society.
Research topics on the Internet.
Trade trips with your peers.