1. Introduction to Welding Tech Connect Welding Tech Connect Welding

2. The Welding Industry Welding has been around since ancient times. The purpose of welding is to join metal parts or pieces together. Some of the industries that employ welders include automobile, heavy equipment manufacturers, power companies, oil and gas, aerospace, and manufacturing.

3. Welding Processes Oxyfuel Gas Welding (OFW) Also known as “oxyacetylene welding”Also known as “oxyacetylene welding” Uses an oxyfuel gas flameUses an oxyfuel gas flame Can be applied with or without pressureCan be applied with or without pressure Can be applied with or without the use of filler materialsCan be applied with or without the use of filler materials

4. Shielded Metal Arc Welding (SMAW) Also known as “stick welding”Also known as “stick welding” Uses an arc between a covered electrode and a workpieceUses an arc between a covered electrode and a workpiece Shielding is obtained from decomposition of the electrode coverShielding is obtained from decomposition of the electrode cover Pressure is not usedPressure is not used Welding Processes (continued) Filler metal is obtained from the electrodeFiller metal is obtained from the electrode

5. Shielded Metal Arc Welding (SMAW) (continued) Is popular because it can be used in the field without complicated equipment and gasesIs popular because it can be used in the field without complicated equipment and gases Mainly used for repair work and occasional weldingMainly used for repair work and occasional welding Welding Processes (continued)

6. Gas Tungsten Arc Welding (GTAW) Also known as Tungsten Inert Gas (TIG) welding, Heliarc, or HeliweldAlso known as Tungsten Inert Gas (TIG) welding, Heliarc, or Heliweld Uses an arc between a nonconsumable tungsten electrode and a workpieceUses an arc between a nonconsumable tungsten electrode and a workpiece Shielding is obtained from a gasShielding is obtained from a gas Can be applied with or without a filler metalCan be applied with or without a filler metal Welding Processes (continued)

7. Gas Tungsten Arc Welding (GTAW) (continued) Welding Processes (continued) Used in the food, aerospace and nuclear industriesUsed in the food, aerospace and nuclear industries Commonly used to weld aluminum, magnesium, copper, and thin sections of stainless steelCommonly used to weld aluminum, magnesium, copper, and thin sections of stainless steel

8. Gas Metal Arc Welding (GMAW) Also known as Metal Inert Gas (MIG) welding, or Metal Active Gas (MAG) weldingAlso known as Metal Inert Gas (MIG) welding, or Metal Active Gas (MAG) welding Uses an arc between a continuous filler metal and a workpieceUses an arc between a continuous filler metal and a workpiece Shielding is obtained entirely from an externally supplied gasShielding is obtained entirely from an externally supplied gas Used in the automobile industry, high- production manufacturing and constructionUsed in the automobile industry, high- production manufacturing and construction Welding Processes (continued)

9. Flux-Cored Arc Welding (FCAW) Uses an arc between a continuous filler metal electrode and a workpieceUses an arc between a continuous filler metal electrode and a workpiece Shielding is provided by a flux contained within the electrodeShielding is provided by a flux contained within the electrode Additional shielding may be obtained from an externally supplied gas or gas mixtureAdditional shielding may be obtained from an externally supplied gas or gas mixture Commonly used in construction because it is a fast welding process and is easily portableCommonly used in construction because it is a fast welding process and is easily portable Welding Processes (continued)

10. Submerged Arc Welding (SAW) Uses an arc between a bare metal electrode and a workpieceUses an arc between a bare metal electrode and a workpiece A layer of granulated mineral material covers the tip of the electrode, the arc, and the workpiece in order to protect the work from contaminations in the airA layer of granulated mineral material covers the tip of the electrode, the arc, and the workpiece in order to protect the work from contaminations in the air Pressure is not usedPressure is not used Filler metal is obtained from the electrode or from a supplemental sourceFiller metal is obtained from the electrode or from a supplemental source Welding Processes (continued) Produces no arc, sparks, splatter or smokeProduces no arc, sparks, splatter or smoke

11. Submerged Arc Welding (SAW) (continued) Welding Processes (continued) Uses a constricted arc between a nonconsumable electrode and a workpiece (transferred arc) or the electrode and a constricting nozzle (nontransferred arc).Uses a constricted arc between a nonconsumable electrode and a workpiece (transferred arc) or the electrode and a constricting nozzle (nontransferred arc). Shielding is obtained from the hot, ionized gas issuing from the torchShielding is obtained from the hot, ionized gas issuing from the torch Shielding gas can be an inert gas or a mixture of gassesShielding gas can be an inert gas or a mixture of gasses Can be applied with or without the use of filler materialCan be applied with or without the use of filler material

12. Soldering A method of bonding two metal surfaces without melting the main workpieceA method of bonding two metal surfaces without melting the main workpiece Produces coalescence of material by using a filler metal, which has a melting point below 842°F (450°C)Produces coalescence of material by using a filler metal, which has a melting point below 842°F (450°C) Primarily used on electrical, electronic, and other small equipmentPrimarily used on electrical, electronic, and other small equipment Soldering, Brazing & Cutting Processes

13. Brazing Like soldering, is also a method of bonding two metal surfaces without melting the main workpieceLike soldering, is also a method of bonding two metal surfaces without melting the main workpiece Used with metals that have higher melting points than used with soldering and produces a stronger bondUsed with metals that have higher melting points than used with soldering and produces a stronger bond Produces coalescence of materials by using a filler metal, which is heated to above 842ºF (450ºC) but below the melting point of the base metalProduces coalescence of materials by using a filler metal, which is heated to above 842ºF (450ºC) but below the melting point of the base metal Soldering, Brazing & Cutting Processes (continued)

14. Cutting processes Oxyfuel Gas Cutting (OFC) – cuts metal by applying heat to cause a chemical reaction between oxygen and the base metalOxyfuel Gas Cutting (OFC) – cuts metal by applying heat to cause a chemical reaction between oxygen and the base metal Carbon Arc Cutting (CAC) – cuts or removes metal by using the heat of the arc between the electrode and the workpiece to cause meltingCarbon Arc Cutting (CAC) – cuts or removes metal by using the heat of the arc between the electrode and the workpiece to cause melting Soldering, Brazing & Cutting Processes (continued)

15. Machine ManufacturersMachine Manufacturers TransportationTransportation Repair ServicesRepair Services Types of Industries That Hire Welders Mining and DrillingMining and Drilling Fabricated MetalsFabricated Metals Metal IndustriesMetal Industries Electrical Equipment ManufacturersElectrical Equipment Manufacturers

16. Depending on the job requirements, work can either be accomplished indoors or outdoorsDepending on the job requirements, work can either be accomplished indoors or outdoors Employees normally work in 8-hour shifts with a 40-hour work weekEmployees normally work in 8-hour shifts with a 40-hour work week Employees usually work alone with very little social contactEmployees usually work alone with very little social contact Working Conditions in the Field of Welding Safety equipment is required, such as safety shoes, goggles, and hoodsSafety equipment is required, such as safety shoes, goggles, and hoods

17. Exposure to hazards is possible, such as contaminants, hazardous equipment, extremely bright light, or loud noise levelsExposure to hazards is possible, such as contaminants, hazardous equipment, extremely bright light, or loud noise levels Physical demands include using hands, standing for long periods of time, repetitive movements, bending, kneeling, stooping, crouching, crawling, climbing, or liftingPhysical demands include using hands, standing for long periods of time, repetitive movements, bending, kneeling, stooping, crouching, crawling, climbing, or lifting Working Conditions in the Field of Welding (continued) Jobs may require working with different materials such as plastic, titanium, aluminum, or steelJobs may require working with different materials such as plastic, titanium, aluminum, or steel

18. Physical traits Good physical condition that enables bending, stooping, and holding uncomfortable positions for a long period of timeGood physical condition that enables bending, stooping, and holding uncomfortable positions for a long period of time Good eyesightGood eyesight Good hand-eye coordinationGood hand-eye coordination Requirements for Becoming a Welder Working well with your handsWorking well with your hands

19. Education High school diploma or GEDHigh school diploma or GED Training through one or more of the following:Training through one or more of the following: -Academic programs -On-the job training -Apprenticeship training -Military training Requirements for Becoming a Welder (continued)

20. Personal traits and abilities Requirements for Becoming a Welder (continued) Maintain a detail-oriented outlookMaintain a detail-oriented outlook Understand written informationUnderstand written information Visualize objects from drawingsVisualize objects from drawings Ability to add, subtract, multiply, divide quickly and correctlyAbility to add, subtract, multiply, divide quickly and correctly Organize work without direct supervisionOrganize work without direct supervision Acquire needed information when necessaryAcquire needed information when necessary Perform repetitive activitiesPerform repetitive activities

21. Personal traits and abilities (continued) Requirements for Becoming a Welder (continued) Concentrate while performing a task without being distractedConcentrate while performing a task without being distracted Follow procedures carefullyFollow procedures carefully Notice when something is wrong or likely to go wrongNotice when something is wrong or likely to go wrong Judge the value of your own workJudge the value of your own work

22. Learned Skills Requirements for Becoming a Welder (continued) Use and handle different tools and equipmentUse and handle different tools and equipment Determine correct tools to use for each jobDetermine correct tools to use for each job Read and interpret blueprintsRead and interpret blueprints Understand arc, gas, and resistance welding theoryUnderstand arc, gas, and resistance welding theory Follow specifications to lay out, cut and form metalsFollow specifications to lay out, cut and form metals Use the different types of welding processesUse the different types of welding processes Correctly operate machineryCorrectly operate machinery

23. Learned Skills (continued) Requirements for Becoming a Welder (continued) Install and repair machinery and equipmentInstall and repair machinery and equipment Perform special processes such as welding studs and brazingPerform special processes such as welding studs and brazing Ensure quality products before, during and after weldingEnsure quality products before, during and after welding

24. The Work Process of Welding Materials Read the given blueprint or detailed work order to plan what needs to be doneRead the given blueprint or detailed work order to plan what needs to be done Determine the correct tools to useDetermine the correct tools to use Put on personal protective clothing and equipmentPut on personal protective clothing and equipment Properly set up the necessary equipmentProperly set up the necessary equipment Position and secure the workpiece using a hoist, hand tools, or other equipmentPosition and secure the workpiece using a hoist, hand tools, or other equipment Clean the surface of the metals using appropriate tools or chemicalsClean the surface of the metals using appropriate tools or chemicals

25. The Work Process of Welding Materials (continued) Start the equipment and ignite the torchStart the equipment and ignite the torch Adjust valves and regulate flow of gas and airAdjust valves and regulate flow of gas and air Weld the metal parts togetherWeld the metal parts together When job is completed, use hand or power tools to chip or grind off excess weld or solderWhen job is completed, use hand or power tools to chip or grind off excess weld or solder Examine the welded materials to verify the final product meets outlined requirementsExamine the welded materials to verify the final product meets outlined requirements

26. Purpose of standards Describe the technical requirements for a material, process, product, system, or serviceDescribe the technical requirements for a material, process, product, system, or service Indicate the procedures, methods, equipment, and tests that should be used to verify the requirements have been metIndicate the procedures, methods, equipment, and tests that should be used to verify the requirements have been met Welding Standards

27. Types of standards Codes – Indicate mandatory materials and actions when completing a specific processCodes – Indicate mandatory materials and actions when completing a specific process Specifications – Indicate mandatory materials and actions when working with a specific productSpecifications – Indicate mandatory materials and actions when working with a specific product Welding Standards (continued)

28. Important standards Standard for Welding Procedure and Performance QualificationStandard for Welding Procedure and Performance Qualification Standard Symbols for Welding, Brazing, and Nondestructive ExaminationStandard Symbols for Welding, Brazing, and Nondestructive Examination Welding Standards (continued) Standard Welding Terms and DefinitionsStandard Welding Terms and Definitions

29. Free Enterprise in the Welding Industry In 2004, there were 429,000 welding, soldering, and brazing workers in the United StatesIn 2004, there were 429,000 welding, soldering, and brazing workers in the United States Approximately 7% of workers are self-employedApproximately 7% of workers are self-employed By 2010, there will be a shortage of approximately 250,000 qualified weldersBy 2010, there will be a shortage of approximately 250,000 qualified welders The need for less skilled welders will decrease as more processes become automated, and the need for highly skilled welders with formal training will increaseThe need for less skilled welders will decrease as more processes become automated, and the need for highly skilled welders with formal training will increase

30. Free Enterprise in the Welding Industry (continued) Manufacturing industries currently employ the largest number of workers, however this market will decline as jobs move overseasManufacturing industries currently employ the largest number of workers, however this market will decline as jobs move overseas Growth over the next 10 years will occur in the construction industryGrowth over the next 10 years will occur in the construction industry Welding, soldering, and brazing jobs as a whole are expected to grow slower than average through 2014Welding, soldering, and brazing jobs as a whole are expected to grow slower than average through 2014

31. Free Enterprise in the Welding Industry (continued) Most welders work 40 hours a week but overtime is common, with some workers putting in up to 70 hours a week. Shift workers can work 12 hour shifts in factories that operate 24 hours a day.Most welders work 40 hours a week but overtime is common, with some workers putting in up to 70 hours a week. Shift workers can work 12 hour shifts in factories that operate 24 hours a day. Hourly pay rates usually range from $11.90 to $18.05Hourly pay rates usually range from $11.90 to $18.05

32. © 2008 Oklahoma Department of Career and Technology Education