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Introduction to Welding
NEW TERMS THE WELDING PROCESS

certified welder electrode filler metal flux fusion inert gas welding rod weldment

Advances in the art of extracting metals from ores have helped make our modern way of living possible. Today's increased knowledge of electronics along with atomic research, gives technologists and scientists great opportunities and responsibilities. The art of producing new metals, as well as joining metals, is as important for survival in our space-age society as it was to the people of ancient times. Although steel is now the basic metal of our industrial economy, scientific advances must be made not only in the search for new metals, but in the processes needed to join these metals. The earliest method of joining two pieces of metal into a unit was by heating them and allowing them to melt together. This union, known as fusion, has changed little from ancient times. Forging, as done in the past by blacksmiths, is a type of fusion. Today, heat for fusing the joint during welding comes from a burning gas or an electric current. Many fuel gases can be used, but Mapp and acetylene are the most popular, Fig. 1-1. Fuel gases are combined during welding with pure oxygen (thus the name oxy-acetylene, for example). The addition of oxygen produces a hotter flame. Electric current is now the .most commonly used heat source. The current is produced by a generator and travels through

Introduction to Welding filler metal. Filler metal may come in the forrn^ orwelcfing~=fbds ^wjiiciuare^dipped^nto the molten joint as it is welded, or iFmay come ifi the form of electrodes which not only carry the electric current but also melt down as the weld proceeds. Most metals will corrode when they are exposed to air or moisture. For example, iron rusts and aluminum produces a white film. Heat speeds up corrosion. If corrosion or dirt or other impurites get into the welded joint, it will be weakened and may not bear the weight it should or stand up to pressure. When the joint is part of a high-rise apartment or a pipeline carrying fuel gas to homes, the problem becomes very serious. To keep air and moisture out of the hot metal while it is being arc welded, two methods are used:
1. A flux is added to the filler metal, coated on or imbedded in the electrode, or used as a blanket over the weld area. A flux is a substance which slows down corrosion. It comes -in powder or liquid form. Submerged arc welding, for example, is done under a blanket of flux, Fig. 1-3. 2. An inert gas, one which does not interact chemically with other elements and will not burn, such as argon or helium, is blown out through the torch around the electric arc. This gas shields the weld from the air, Fig. 14. Some welding is done inside a sealed room filled with such a gas, and the welder must wear an oxygen mask. Two processes which have grown up out of this shielding principle are: TIG welding - Tungsten Inert Gas (the electrode is made of tungsten) MIG welding - Metal Inert Gas (the electrode may be one of many metals) These processes differ in the types of metal on which they work best.

1 - 1 . This welder is using an oxy-acetylene torch to cut a section from an automobile.

cables to the torch. At the end of the torch is the electrode, a rod of a material which will conduct electricity. Electrode materials vary according to the job they must do. Once the current is turned on, the electrode touches the metal joint for only an instant to establish contact. Then it is pulled back a little, but the electric current continues to flow, jumping over the gap. As it jumps the gap, the sparks form tiny arcs. That's where the name arc welding comes from, Fig. 1-2.
ELECTRODE FLUX COATING CORE WIRE ARC STREAM FLUX SHIELD
ARC PENETRATION

MOLTEN POOL WELD DEPOSIT

MELTING INTO METAL

BASE METAL

1-2. The electric current jumps the gap between the torch and the workpiece.

Sometimes two pieces of metal are simply melted together. More often, additional metals are added during melting to produce a stronger joint. This additional metal is called

The newer types of weldingplasma arc, laser, and electron beamare variations on the basic welding principles. Lasers are highly concentrated beams of light but are not yet practical because the equipment is very expensive. Electron beams are similar to laser beams, but they must be focused in a vacuum. Plasma arc is created by running the electric current through a certain type of gas. When this happens, the gas superheats and its atoms

Welding Technology

1-3. Submerged arc welding is done under a blanket of flux.

MOLTEN WELD METAL SHIELDING GAS SOLIDIFIED " WELD METAL

NOZZLE

1 -4.

Inert gas shields the weld from the atmosphere.

1 -5. Cracks around a weld joint which could have been prevented.

change, turning it into what is called plasma. The plasma creates the heat which fuses the weld joint. The act of welding is a simple process, but a welder has to know many things which can make welding a complex process. For example,
metals are different and do not all melt at the same rate or mix together equally well all metals corrode and corrosion can be prevented or controlled in many ways the welder's technique can either improve or weaken the joint all metals warp when heated. If you've ever taken a hot pan out of the oven and plunged it into water, you've seen and heard it curl up. If a metal joint is held down and not allowed to warp or is not compensated in some way, the warp remains in the metal, and it works away at the metal until the joint or some other part cracks, Fig. 1-5.

The relationships of various welding processes are shown in Fig. 1-6. Those just discussed and many others will be covered in detail throughout the text. Originally, welding was done mainly to repair damaged or worn metal parts. However, improvements in welding processes have increased its use. Most assemblies today whose component parts are joined by welding, known as a weldment, would have been bolted or riveted a few years ago. The introduction of laser and electron beam welding promises even more advancement. Welding has also gained in popularity because it is a fast, economical method for both fabrication and repair. For instance, a machine part may consist of many pieces. When those pieces can be welded, the need for fasteners, such as rivets, is eliminated. Many

Introduction to Welding

MASTER CHART

OF
WELDING PROCESSES

1-6.

A master chart of welding processes. (American Welding Society)

other machine parts are cast in a single piece. Castings require special designs and molds, and, when they are worn or damaged, the entire casting may have to be replaced. Welding, however, makes it possible for the same machine part to be constructed of several standard pieces which require no special designs and which can be replaced where needed while retaining any other pieces still usable.
CAREERS IN WELDING

Of course, the greatest numbers of welders are needed in heavily populated areas, but, in general, most are employed in the middle west, especially Detroit and Chicago. The next largest numbers are used in the northeast and the southwest. If the trend toward reduced job opportunities in the auto industry continues, this distribution may change.
Certification

Welders are needed in many industries. Many welders find employment in general repair shops, Fig. 1-7. Such shops use various equipment and procedures which give welders good experience.

Once you have decided that welding is the career you are most interested in, you should decide what level of skill you wish to acquire. For example, welders who work in nuclear plants or on aircraft must have better skills than those whose work does not involve human safety, Fig. 1-8. There are also jobs which relate to welding but which may not demand the very best welding skills. A welding supervisor, for example, may not make the best welds but must be a good judge of other people's work and must have organizational and teaching abilities.

1-7.

Repair shop welding provides good experience.

The construction industry employs a large percentage of today's welding personnel. Highway maintenance and repair, bridge and building construction, and oil industry equipment production fall into this category. In these areas where work is covered by codes, welders receive in-plant training for specific jobs. The automotive industry employs a large percentage of welders, many of whom have received special in-plant training on semiautomatic and automatic welding machines. Robot welding machines, however, will no doubt limit the number of trainees required in the near future. Oil and gas pipelines also require welders for production and repair.

1 -8. Because she works on aircraft, this welder must be certified.

To be a qualified welder, you must have enough training and skill to make a weld which meets job specifications. A certified welder, however, is one who has made welds

according to certain established standards and who has a written certificate testifying to that fact. The type of welding and the legal restrictions of the area in which it is done determine requirements. Certification is carried out by testing organizations, such as the American Welding Society, manufacturers, and contractors. Welders may not be qualified or certified on their own. It is important to realize that certification under one set of standards may not qualify you to weld under another set, even though the jobs are alike. Always find out the rules which apply to the job in question and make sure you can fulfill all the requirements. Welders should become familiar with the American Welding Society and the Society of Mechanical Engineer's codes as well as the specific code under which they wish to qualify. Training Different levels of welding training are available through high school classes, trade

and vocational schools, colleges and universities, and company schools. Most training schools provide the student with sufficient skill for non-certified welding jobs. Such welders are employed by large and/or small companies and trained in-plant for specific jobs. Some vocational programs develop students capable of passing tests set by the American Welding Society or private companies. Welders experienced in many industries are constantly required for supervisory positions. Many colleges and vocational schools have specialized courses for those interested in supervision or welding inspection.

Discussion Questions
1. What is the difference between a qualified welder and a certified welder? 2. What are inert gases used for during welding? Why? 3. What are the advantages of welding for fabrication and repair? 4. Name several industries which employ welders.