An integrated lesson

Introduction
What is Arc Welding?
Why is Welding Important?
Why Learn to Weld?
Basic Electricity and the Science of Welding
Electricity
Energy Transfers
Changes of State
Chemical Reactions
Welding Safety
Careers in Welding

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 Arc welding is a process used to join two pieces
of metal together.
How does it work?
A welder creates an electric arc that melts the metal
and filler rod to create a pool of molten metal that
hardens to fuse the two pieces of metal together.
 Why is welding important?
Many of the things you use need to be welded.
Your parents car
Power line towers
Your school desk
Your bicycle www.topspeed.com

dcist.com assembly.state.ny.us
www.cunninghamcycles.com
 Why Learn to Weld?
Welding can help build a successful career to earn
money to buy the things you want.
Skilled Welders are in high demand.
Welding is challenging and high tech.

www.universalwelding.com
www.weldingschools.com
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 Voltage The electrical potential or pressure
that causes current to flow
Measured in Volts
Current The movement of charged particles
in a specific direction
Measured in Amps DC+
DC -
Polarity
DC- (Direct Current
Electrode Negative)
DC+ (Direct Current
AC
Electrode Positive)
AC (Alternating Current)
 The electricity flows from the power source,
through the electrode and across the arc,
through the base material to the work lead and
back to the power source

Circuit click on the link

to learn more.
Circuit Info.
 Use the following links to learn how electricity
works in a circuit
Conductors, Insulators, and electron flow
Current and Voltage in a Circuit
Resistance
Ohms Law
 The electron flow you just learned about is
what creates the arc in arc welding.
This is a form of electrical energy
How do we use that electrical energy to fuse metals
together?
 The energy transfers that take place in welding

Electrical The arc created by the

electric current is
converted into heat
Thermal because of the
resistance of electron
flow. The heat melts
the metal to fuse it
together.
 Here are some places to look to learn more
about energy and energy transfers.
Forms of Energy
Energy Transformations
 Changes of State and Chemical Reactions
During the welding process the metal changes states
or forms.
What are the states of matter?
Solid
Liquid
Gas
Plasma

Click here to learn more about the changes of state

 Changes of State and Chemical Reactions
So what changes of state occur during welding?
Initially the metal is a solid
When the arc starts the solid is converted into a liquid
Some of the liquid is converted into a gas vapor
When the arc stops the liquid cools to form a solid
again this is the newly formed weld joint

Solid Liquid Solid

(gas vapor)
 Changes of State and Chemical Reactions
Chemical Reactions
During the welding process certain chemical reactions
take place.
Hydrogen, Oxygen, and Nitrogen can react in the weld
puddle and cause changes in the structure of the weld
weakening the weld.

pt.chemicalstore.com
 Because of the chemical reactions, energy transfers, and
electricity involved in welding proper safety must be
addressed
Welding can be safe when sufficient measures are
taken to protect yourself and others from potential
hazards
Students should read and understand the following
before welding:
Warning Labels
Material Safety Data Sheets (MSDS)
Students should also be familiar with the following
information
Safety in Welding, Cutting, and Allied Processes (ANSI Z49.1)
Lincoln Electrics Arc Welding Safety (E205)
http://www.lincolnelectric.com/knowledge/training/weldcurriculum.asp
 Understand and follow all warning labels
found:
On welding equipment
With all consumable packaging
Within instruction manuals

www.jpbrandit.com
http://www.lincolnelectric.com/knowledge/training/weldcurriculum.asp
 Material Safety Data
Sheets (MSDS) are:
Required by law and
OSHA
Created by the
manufacturer of a
product per OSHA
guidelines
Designed to inform
users
Shipped with every box
of consumable product
Available free online at:
www.lincolnelectric.com/produc
ts/msds/

http://www.lincolnelectric.com/knowledge/training/weldcurriculum.asp
 MSDS outlines a
products:
Identity and
composition
Potential hazards
Safe use
Handling
information
Manufacturer
contact information

http://www.lincolnelectric.com/knowledge/training/weldcurriculum.asp
 Protect yourself and
others from
potential hazards
including:
Fumes and Gases
Electric Shock
Arc Rays
Fire and Explosion
Hazards
Noise
Hot objects

http://www.lincolnelectric.com/knowledge/tra
 Fumes and gases can be
hazardous to your health
Keep your head out of the
fumes
Use enough ventilation,
exhaust at the arc, or both,
to keep fumes and gases
from your breathing zone
and the general area
See product labeling and
MSDS for ventilation and
respirator requirements

http://www.lincolnelectric.com/knowledge/training/weldcurriculum.asp
 Electric shock can kill
Do not touch live
electrical parts
Primary Voltage 230,
460 volt input power
Secondary Voltage 6
to 100 volts for welding
Insulate yourself from
work and ground
Follow all warnings
on welding
equipment

http://www.lincolnelectric.com/knowledge/training/weldcurriculum.asp
 Welding sparks can cause
fires and explosions
Sparks and spatter from
the welding arc can spray
up to 35 feet from your
work
Flammable materials
should be removed from
the welding area or
shielded from sparks and
spatter
Have a fire extinguisher
ready
Inspect area for fires 30
minutes after welding

http://www.lincolnelectric.com/knowledge/training/weldcurriculum.asp
 Welders must wear
protective clothing for
Protection from sparks, spatter
and UV radiation
Insulation from electric shock

Protective clothing
includes
Fire-proof clothing without
rolled sleeves, cuffs or frays
Work boots
Welding gloves, jackets, bibs,
and fire-proof pants
Welding cap, helmet and
safety glasses
Ear protection ear plugs and
muffs

http://www.lincolnelectric.com/knowledge/training/weldcurriculum.asp
 Education Careers
Penn College of American Welding
Technology Society
Penn College Career Guide
Welding Video Welding Jobs
Welding Schools

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www.sun-tech.org
 Here are some possible areas you can start a career
in welding
Racing
Engineering
Farm
Auto Technician
Sculpting
Maintenance
Iron worker
Robotics
Production welder
Fabricator
And many more
 Do you want to learn more about welding and
how to weld? If so, go to the link below for
more information on how to weld.
This is to be used if your school has access
http://www.lincolnelectric.com/knowledge/t
raining/weldcubrriculum.asp
 http://www.lincolnelectric.com/knowledge/t
raining/weldcurriculum.asp
http://www.weldinginfocenter.org/sci_tech/i
ndex.html
http://www.pct.edu/degreesthatwork/weldi
ng.htm
http://www.allaboutcircuits.com/vol_1/inde
x.html
All photographs are cited next to photograph