1. Welding
Mr. Huebsch

2. Behavioral Objectives
Metal Basics
Welding Equipment
Welding Safety
ARC Welding
MIG Welding
Welding Education

3. Metal Basics
Metals come from natural deposits of ore in the earth’s crust.
Two methods of mining open pit and underground ore are
Selective – precise veins are worked (high grade)
Bulk – Large quantities (low grade)
Two types of ore are
Ferrous – high iron content, 20x more abundant than non- ferrous, magnetic
Non-Ferrous – low or no iron content, not magnetic

4. Metal Basics Types of Metal Ferrous (iron) Non-Ferrous (no iron)
Cast Iron
Mild Steel
Stainless steel
Wrought Iron
Carbon Steel
Forged Steel
Titanium
Non-Ferrous (no iron)
Aluminum
Brass
Copper
Gold
Silver
Lead
Magnesium

5. Metal Basics Ice Steel Solid, Liquid, Gas
Like ice metal can exist in these three stages
Ice
Solid below its 32° Fahrenheit melting point
Heat to 32° and up it turns to water
Heat to 212°, begins to boil and vaporize
Steel
Solid at or below 2,786°
Heat to 2,786° and it turns to a liquid or molten
Heat over 5,500° begins to vaporize

6. Metal Basics Heat Control
Too cold won’t weld
Too hot and vaporize the metal
Different fuels offer different tempts
Color of metal can indicate tempt.
Refer to charts and keep in shop
To control the weld puddle, you must learn how to judge and control the temp. of the metal you’re welding!

7. Welding Equipment Oxyacetylene Brazing & Soldering Arc Welding
SMAW (Shield metal arc welding)
MIG Welding (GMAW) Gas Metal Arc Welding
TIG Welding (Tungsten Inert Gas) Tig Video
Spot Welding
EBW (Electron Beam Welding) thin electron beam used to fusion weld two or more parts together when other methods won’t work.

8. Arc Welding AC or DC Power source Electrode Cable Electrode Holder
2.2.3 Electrode Holder - The electrode holder connects to the welding cable and con- ducts the welding current to the electrode.  The insulated handle is used to guide the electrode over the weld joint and feed the electrode over the weld joint and feed the electrode into the weld puddle as it is consumed.  Electrode holders are available in different sizes and are rated on their current carrying capacity.
2.2.4 Ground Clamp - The ground clamp is used to connect the ground cable to the work piece.  It may be connected directly to the work or to the table or fixture upon which the work is positioned.  Being a part of the welding circuit, the ground clamp must be capable of carrying the welding current without overheating due to electrical resistance.
2.2.5 Welding Cables - The electrode cable and the ground cable are important parts of the welding circuit.  They must be very flexible and have a tough heat-resistant insulation. Connections at the electrode holder, the ground clamp, and at the power source lugs must be soldered or well crimped to assure low electrical resistance.  The cross-sectional area of the cable must be sufficient size to carry the welding current with a minimum of voltage drop. Increasing the cable length necessitates increasing the cable diameter to lessen resistance and voltage drop.  
2.2.6 Coated Electrodes - Various types of coated electrodes are used in shielded metal arc welding.  Electrodes used for welding mild or carbon steels are quite different than those used for welding the low alloys and stainless steels.  Details on the specific types will be covered in subsequent lessons.
Ground Cable
Electrode
Work

9. Arc Welding Coating Core rod Shielding gasses Solidified slag
Molten Pool
Work Piece

10. MIG Welder Metal intert gas – changed to Gas Metal Arc Welding
Metal intert gas – changed to Gas Metal Arc Welding

11. MIG Welder

12. Welding Safety Risks Precautions Ventilation
Explosion
Fire
Eye radiation burns (60 secs.)
Skin Burns
Chemical
Precautions
Ventilation
Boots, leather apron, leather gloves
Eye protection (ultraviolet light)
Skin Burns

13. Welding Safety

14. Welding Education Learn in a formal classroom On the job training
If you are Considering a career in welding check out this web site.
Education-Portal.com gives a great overview of welding educational requirements.
portal.com/welding_education.html