Welding is a fabrication or sculptural process that joins materials,

usually metals or thermoplastics, by causing fusion, which is distinct from lower

temperature metal-joining techniques such as brazing and soldering, which do
not melt the base metal. In addition to melting the base metal, a filler material is often
added to the joint to form a pool of molten material (the weld pool) that cools to form
a joint that can be as strong as the base material. Pressure may also be used in
conjunction with heat, or by itself, to produce a weld.
Some of the best known welding methods include:
Shielded metal arc welding (SMAW) - also known as "stick welding or electric
welding", uses an electrode that has flux, the protectant for the puddle, around
it. The electrode holder holds the electrode as it slowly melts
away. Slag protects the weld puddle from atmospheric contamination.
Gas tungsten arc welding (GTAW) - also known as TIG (tungsten, inert gas),
uses a non-consumable tungsten electrode to produce the weld. The weld area
is protected from atmospheric contamination by an inert shielding gas such
as Argon or Helium.
Gas metal arc welding (GMAW) - commonly termed MIG (metal, inert gas),
uses a wire feeding gun that feeds wire at an adjustable speed and flows
an argon-based shielding gas or a mix of argon and carbon dioxide (CO2) over
the weld puddle to protect it from atmospheric contamination.
Flux-cored arc welding (FCAW) - almost identical to MIG welding except it
uses a special tubular wire filled with flux; it can be used with or without
shielding gas, depending on the filler.
Submerged arc welding (SAW) - uses an automatically fed consumable
electrode and a blanket of granular fusible flux. The molten weld and the arc
zone are protected from atmospheric contamination by being "submerged"
under the flux blanket.
Electroslag welding (ESW) - a highly productive, single pass welding process
for thicker materials between 1 inch (25 mm) and 12 inches (300 mm) in a
vertical or close to vertical position.
Many different energy sources can be used for welding, including a gas flame,
an electric arc, a laser, an electron beam, friction, and ultrasound. While often an

industrial process, welding may be performed in many different environments,

including in open air, under water, and in outer space. Welding is a hazardous
undertaking and precautions are required to avoid burns,electric shock, vision
damage, inhalation of poisonous gases and fumes, and exposure to intense ultraviolet
radiation.
Until the end of the 19th century, the only welding process was forge welding,
which blacksmiths had used for centuries to join iron and steel by heating and
hammering. Arc welding andoxyfuel welding were among the first processes to
develop late in the century, and electric resistance welding followed soon after.
Welding technology advanced quickly during the early 20th century as World War I
and World War II drove the demand for reliable and inexpensive joining methods.
Following the wars, several modern welding techniques were developed, including
manual methods like SMAW, now one of the most popular welding methods, as well
as semi-automatic and automatic processes such as GMAW, SAW, FCAW and ESW.
Developments continued with the invention of laser beam welding, electron beam
welding, magnetic pulse welding (MPW), and friction stir welding in the latter half of
the century. Today, the science continues to advance. Robot welding is commonplace
in industrial settings, and researchers continue to develop new welding methods and
gain greater understanding of weld quality.
DRAWING
Arc welding is a type of welding that uses a welding power supply to create an electric arc between
an electrode and the base material to melt the metals at the welding point. They can use
either direct (DC) or alternating (AC) current, and consumable or non-consumable electrodes. The
welding region is usually protected by some type of shielding gas, vapor, or slag. Arc welding
processes may be manual, semi-automatic, or fully automated. First developed in the late part of the
19th century, arc welding became commercially important in shipbuilding during the Second World
War. Today it remains an important process for the fabrication of steel structures and vehicles.

Spot welding is typically used when welding particular types of sheet metal, welded wire
mesh or wire mesh. Thicker stock is more difficult to spot weld because the heat flows into the
surrounding metal more easily. Spot welding can be easily identified on many sheet metal goods,
such as metal buckets. Aluminium alloys can be spot welded, but their much higher thermal
conductivity and electrical conductivity requires higher welding currents. This requires larger, more
powerful, and more expensive welding transformers.

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Oxyacetylene gas welding is commonly used to permanently join mild steel. A mixture of
oxygen and acetylene, burns as an intense / focussed flame, at approximately 3,500 degrees
centigrade. When the flame comes in contact with steel, it melts the surface forming a molten
pool, allowing welding to take place. Oxyacetylene can also be used for brazing, bronze
welding, forging / shaping metal and cutting.

Shielded metal arc welding (SMAW), also known as manual metal arc
welding (MMA or MMAW), flux shielded arc welding[1] or informally as stick welding, is a
manual arc welding process that uses a consumable electrode covered with a flux to lay the weld.
An electric current, in the form of either alternating current or direct current from a welding power
supply, is used to form an electric arc between the electrode and the metals to be joined. The
workpiece and the electrode melts forming the weld pool that cools to form a joint. As the weld is
laid, the flux coating of the electrode disintegrates, giving off vapors that serve as a shielding
gas and providing a layer of slag, both of which protect the weld area from atmospheric
contamination.
Because of the versatility of the process and the simplicity of its equipment and operation, shielded
metal arc welding is one of the world's first and most popular welding processes. It dominates other
welding processes in the maintenance and repair industry, and though flux-cored arc welding is

growing in popularity, SMAW continues to be used extensively in the construction of heavy steel
structures and in industrial fabrication. The process is used primarily to
weld iron and steels (including stainless steel) butaluminium, nickel and copper alloys can also be
welded with this method

TIG Welding is a manual welding process that requires the

welder to use two hands to weld. What separates TIG welding
from most other welding processes is the way the arc is created
and how the filler metal is added! When TIG Welding one hand
is used for holding the TIG torch that produces the arc and the
other hand is to add the filler metal to the weld joint. Because
two hands are required to weld; TIG welding is the most difficult
of the processes to learn, but at the same time is the most
versatile when it comes to different metals. This process is slow
but when done right it produces the highest quality weld! TIG
welding is mostly used for critical weld joints, welding metals
other than common steel, and where precise, small welds are
needed.
Clothing
Q: What is the most common injury to a welder?
A: Burns are the most common injury to welders due to sparks landing on the skin. Welding arcs are very intense and can
cause burns to skin and eyes with just a few minutes of exposure.
Q: What protective clothing is needed in arc welding?
A: Protective clothing needed for welding includes general fire resistant clothing, safety glasses, shoes, gloves, helmet and
leathers.
Q: Can oxy-fuel tinted goggles be used to protect your eyes while arc welding?
A: No, oxy-fuel goggles do not protect your eyes from the intense ultraviolet radiation (UV) produced by the welding arc. A
welding helmet with the proper shaded lens must be used whenever welding.
Q: What types of fabric are recommended for clothing worn when arc welding?
A: Because of its durability and resistance to fire, wool clothing is suggested over synthetics. Synthetics should never be
worn because it melts when exposed to extreme heat. Cotton can be worn if it is specially treated for fire retardation.
Q: What are steps that you can take to prevent hot sparks from being trapped in your clothing?

A: Avoid rolling up your sleeves or pant cuffs, because sparks or hot metal could deposit in the folds. Also, wear your pants
outside your work boots, not tucked in, to keep particles from falling into your boots.

Safety Glasses
Q: Is it necessary to wear safety glasses if you are already wearing a welding helmet?
A: Even when wearing a helmet, Z87.1 approved safety glasses with side shields, or goggles, should always be worn to
protect your eyes from flying particles.

Shoes
Q: What types of footwear are recommended for welders?
A: Leather boots with six- to eight-inch ankle coverage are the best foot protection. Where heavy work is done, safety-toe
protection boots should be worn. Metatarsal guards over the shoe laces can protect them from falling objects and sparks.

Gloves
Q: What types of gloves are suitable for protecting your hands while welding?
A: Heavy, flame-resistant gloves (from materials such as leather) should always be worn to protect your hands and wrists
from burns, cuts and scratches. As long as they are dry and in good condition, they will offer some insulation against electric
shock.

Helmets and Arc Rays

Q: What are the two forms of radiation given off by the welding arc?
A: The two types of radiation are Infrared (IR) and Ultraviolet (UV) radiation. IR radiation can cause retinal burning and
cataracts. IR can usually be felt as heat. UV radiation, which cannot be felt, can cause an eye burn known as "Welders
Flash."
Q: How can exposure to IR and UV radiation injure your eyes?
A: It is essential that your eyes are protected from radiation exposure. IR radiation can cause retinal burning and cataracts.
IR can usually be felt as heat. UV radiation, which cannot be felt, can cause an eye burn known as "Welder's Flash." This
condition may not be apparent until several hours after exposure. It can cause extreme discomfort and can result in swelling,
fluid excretion and temporary blindness. Normally, "Welder's Flash" is temporary, but repeated or prolonged exposure can
lead to permanent injury of the eyes.
Q: Is it safe to weld without a welding helmet for a brief period of time, such as during tack welding?
A: Even brief exposure to UV rays can result in a burn to the eyes known as "Welders Flash" which may not be evident until

several hours after exposure. It causes extreme discomfort and can result in swelling, fluid excretion from the eyes and even
temporary blindness. Normally, this condition is temporary, but repeated overexposure to UV radiation can result in
permanent eye damage.
Q: How do you select the proper filter lens for your welding helmet?
A: The general rule of thumb is to choose a filter too dark to see the arc and then move to the next lighter setting without
dropping to below the minimum recommended rating.
Q: How can you tell that you are being overexposed to radiation from the welding arc?
A: Infrared (IR) radiation cannot be seen but is felt as heat. And there is no way to sense if you are being overexposed to
Ultraviolet (UV) radiation so just do not take any chances and always wear eye and face protection with the proper
protective shading.
Q: How can overexposure to the UV radiation from the welding arc injure you?
A: UV radiation can also burn exposed skin. This process is similar to getting sunburn from overexposure to the sun. Long
exposure to arc rays without protection can lead to second and third degree skin buns. Repeated overexposure to ultraviolet
radiation is a known cause of skin cancer.
Q: Is it safe to wear contact lenses while arc welding?
A: Welders should be able to wear contact lenses safely in most situations provided they wear appropriate industrial eye
wear and use the protection we've already discussed with respect to protection against arc rays. Anyone wearing contacts
on the job should consult with their company medical staff and their own ophthalmologist.

Noise and Hearing Protection

Q: How can you protect your hearing when arc welding?
A: Earplugs and earmuffs keep metal sparks and airborne particles from entering your ear canal and protect your hearing
from the effects of excessive noise.
Q: How do you know when the noise level to which you are exposed is potentially hazardous?
A: Levels of noise over 85 decibels, averaged over an eight-hour workday, are potentially hazardous to your hearing. When
noise levels are painful or are loud enough to interfere with your ability to hear others speaking at a normal conversational
volume this is an indication that levels are potentially hazardous.
Q: How does exposure to high noise levels damage your hearing?
A: The length and number of times you are exposed to high levels of noise determines the extent of the damage to your
hearing. High noise levels cause damage to the ear drum and other sensitive parts of your inner ear.
Q: In addition to wearing hearing protection, what measures can you take to protect yourself from high noise levels?
A: If it is not possible to reduce the level of noise at the source by moving either yourself or the equipment, or by using
sound barriers, then you should wear adequate ear protection.

Welding Rods
Asbestos in Welding Rods and Other Building
Materials
Welding rods are also known as welding electrodes. Available in a number of different sizes and varieties,
these products are made from various types of metal and an anti-oxidation agent known as "flux." Welding
rods work as a type of "glue" to join two pieces of metal together through the welding process; they
reinforce the bond, making it more durable.
There are four main types of welding rods that are commonly used. The most common type is "6010,"
which is an all-purpose welding rod able to withstand up to 60,000 pounds of pulling force. Other types
include 7018, which is low in hydrogen content and used where moisture is an issue; 308L, used for
welding stainless steel components; and 24 AC/DC, which welders employ when it is necessary to join
two different types of metal.
Asbestos in welding rods was usually part of the flux surrounding the rod itself. It was in part a safety
measure to prevent welding accidents. The other purpose that asbestos served was to add tensile
strength to the final bond; asbestos is a type of stone, and shares that material's durability.
Although most asbestos use in the manufacture of welding products was phased out during the 1980s,
millions of asbestos-containing welding rods were sold before regulations took effect. Even today, more
than two decades later, it is possible that many welding rods of all types are still on hardware and welding
supply store shelves.
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Hazards Associated with Welding Products

Welders are the primary victims of asbestos exposure from the use of asbestos-containing welding rods.
Welding is a very high-heat application and while asbestos is very resistant to heat, under the harsh
conditions of most welding jobs the asbestos in the flux could very easily enter the atmosphere and be
inhaled by the welder or anyone else in the vicinity.

Read more: http://www.mesothelioma.com/asbestos-exposure/products/welding-rods/#ixzz3ndqtJLCl