Arc Welding Basic Safety

Warnings Welding can be safe when proper measures are taken to protect yourself and others from potential hazards. Understand and follow all warning labels found on equipment and with all consumables.

Potential Hazards Protect yourself and others from potential hazards including: Fumes and Gases Electric Shock Arc Rays Fire and Explosion Hazards Noise Hot objects Welding Sparks

Fumes and Gases Welding fumes can be harmful to the welder causing implications such as: Irritation of the respiratory tract Metal fume fever Slightly increase the risk of lung cancer Use enough ventilation, exhaust at the arc, or both, to keep fumes and gases from your breathing zone and the general area Use a respirator if needed or required by the process. The ventilation system must be on while welding at all times.

Electrical Shock Electric shock can kill Do not touch live electrical parts Primary Voltage –208 - 240, 416 - 480 volt input power Secondary Voltage – 6 to 100 volts for welding Insulate yourself from work and ground Follow all warnings on welding equipment Wear insulated clothing Always shut off machinery when done and roll the cords up neatly Do not make repairs yourself, alert your instructor immediately!

U.V. Rays Welding will produce ultraviolet rays that are harmful to the human eye and skin. Proper protection is needed to avoid bodily harm. Arc rays are ten times brighter than the sun and can injure eyes and burn skin Precaution must be taken to protect your eyes and skin from UV radiation. The welding arc is brighter than the sun Wear correct eye and body protection 10 shade helmet Safety Glasses under the helmet Gloves Arm and Body Protection Jacket Shoulder Covers Coveralls

Fire Hazards and Material Safety 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 Always clean painted materials All welding booths should be cleaned thoroughly Have a fire extinguisher ready Inspect area for fires 30 minutes after welding Watch for sharp metal edges Cool all welded metal in the water tank.

Ear Protection Loud noises can damage your hearing Keep loud noises at a safe level by using proper hearing protection such as: Ear plugs Ear muffs

Protective Clothing 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, shirts jackets, bibs, and fire-proof pants Welding cap, helmet and safety glasses Ear protection – ear plugs and muffs Most importantly safety glasses are to be worn at all times in the shop

Improper Protective Clothing List and describe what is wrong in this picture

Basic Electricity and Welding Arc Welding Basic Safety

Arc Welding Circuit and Concept 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. Identify all the above parts for the arc welder, describe the function of each part, and determine each of the parts safety aspects.

Electrical Concepts DC - DC + 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 Polarity DC- (Direct Current Electrode Negative) DC+ (Direct Current Electrode Positive) AC (Alternating Current) ALWAYS REMEMBER THAT VOLTAGE WILL HURT BUT AMPERAGE CAN BE FATAL AC

Electrical Lead Condition Before starting an operation, always check the condition of all electrical leads. Cracked and worn leads can lead to fatal shock. All electrode holders or “stingers” should be in tack and not cracked or missing pieces. All plugs and outlets should be in tack. Never set-up a welder with a broken plug or into a broken outlet. Never operate a welder with splices showing in the leads.

Shielded Metal Arc Welding SMAW

SMAW Process

SMAW Key Parts Electrode Holder: Also known as the “stinger” Handle-like tool that holds the electrode while welding. Never hold this part with your bare hand while welding. Ground Connection: Also known as the “workpiece connection clamp” that connects to the work to complete the electrical circuit Power Source: Where the welder plugs into Amperage Scale: Determines the amount of “heat” or power the welder will operate at. Polarity Switch: Setting that determines how the electrons will flow during the welding process. On / Off Switch: Turns the welder on / off. Make sure the switch function properly at all times.

SMAW Principles The American Welding Society defines SMAW as Shielded Metal Arc Welding SMAW: Is commonly known as ‘Stick’ welding or manual arc welding Is the most widely used arc welding process in the world Can be used to weld most common metals and alloys

SMAW Welding Circuit Current flows through the electrode cable, to the electrode holder, through the electrode, and across the arc On the work side of the arc, the current flows through the base material to the work clamp and back to the welding machine

SMAW Process Identify all the above segments for the SMAW process, describe the function of each segment, and determine if any safety aspects exist.

The Electrode What is it? Is a consumable - it gets melted during the welding process Is composed of two parts Core Rod (Metal Filler) Carries welding current Becomes part of the weld Flux Coating Produces a shielding gas Can provide additional filler Forms a slag

Electrode Classification Electrodes are classified by a numbering system E6013 E = Electrode 60 or first two numbers = Tensile strength (thousands of pounds 1 or third number = Welding position 3 or fourth number = Welding current type and depth of weld penetration. Pictured above are E-7018 electrodes. Identify what the tensile strength is for this electrode.

Electrode Classification Third Digit E_ _ 1 _ = Usable in all directions E_ _ 2 _ = Usable in flat and horizontal positions only E_ _ 4 _ = Usable for vertical down only Pictured above are E-6011 electrodes. Identify what each digit resembles up to the third digit.

Electrode Classification Fourth Digit E_ _ _ 0 = DC reverse polarity only E_ _ _ 1 = AC and DC reverse polarity E_ _ _ 2 = AC and DC straight polarity E_ _ _ 3 = AC and DC E_ _ _ 4 = AC and DC E_ _ _ 5 = DC reverse polarity E_ _ _ 6 = AC and DC reverse polarity E_ _ _ 8 = AC and DC reverse polarity Pictured above are E-6013 electrodes. Identify what each digit resembles.

The Arc An arc occurs when the electrode comes in contact with the work-piece and completes the circuit … like turning on a light! The electric arc is established in the space between the end of the electrode and the work The arc reaches temperatures of 10,000°F which melts the electrode and base material Don’t look at the arc without proper eye protection. Wear proper body protection. The UV rays will cause bodily harm. Arc burning off the electrode

Weld Puddle As the core rod, flux coating, and work pieces heat up and melt, they form a pool of molten material called a weld puddle The weld puddle is what a welder watches and manipulates while welding Don’t touch the hot puddle!!! The metal is hot!!!

Shielding Gas A shielding gas is formed when the flux coating melts. 2 3 Shielding Gas 4 A shielding gas is formed when the flux coating melts. This protects the weld puddle from the atmosphere preventing contamination during the molten state Don’t touch the metal!!! The metal is hot!!! Shielding gas can cause bodily harm. Be sure proper ventilation is being used. The shielding gas protects the molten puddle from the atmosphere while stabilizing the arc

Solidified Weldment As the molten weld puddle solidifies, it forms a joint or connection between two pieces of base material When done properly on steel, it results in a weld stronger than the surrounding base metal Don’t touch the metal!!! The metal is hot!!!

Slag Slag is a combination of the flux coating and impurities from the base metal that float to the surface of the weld. Slag quickly solidifies to form a solid coating which slows the cooling rate of the weld The slag can be chipped away and cleaned with a wire brush when hard Don’t touch the metal!!! The metal is hot!!! Slag can be dangerous when being removed. Wear the proper safety protection. This welder chips the slag off of a weld during the repair of railroad tracks

OXY ACETYLENE SET-UP

Terms and Definitions Backfire: A short pop of the torch flame followed by extinguishing of the flame or continued burning of the gases. Flashback: when the torch flame moves into or beyond the mixing chamber. Preheating: Heating prior to a welding or cutting operation

Equipment Required Oxygen cylinder Acetylene cylinder Pressure regulators Two hoses encased together Welding torch with tips Welding goggles and safety glasses Striker Check valves to prevent flashback

Acetylene Regulator

Oxygen Regulator

Typical Torch

Torch Parts

Striker

Cutting Tip

Welding and Heating Tips

Check Valves

Safety Rules for Oxy-Acetylene Workplace Keep the work area free of grease, oil, and flammable materials Cool or quench hot metal and extinguish all sparks before leaving. Sparks can travel up to 35 feet. Don’t leave torches, or hot metal where someone will pick them up Never carry matches or lighters into any work area

Pressure Gauge Failure

Cracked Acetylene Hose

Improper Storage of Tanks

Oxygen/ Acetylene Cutting Torch Stored on Unsafe Cart

Oxygen/ Acetylene Cutting Torch Stored in Flammable Liquids Cabinet

Regulator Parts Pressure regulators reduce the supply pressure, indicated by the high pressure gauge to suitable working pressure, indicated by the low pressure gauge. By turning the adjusting screw, proper working pressures can be achieved.

Personal Safety Shirts Pants or Coveralls Shoes Gloves Safety Glasses keep collar and sleeves buttoned to keep out sparks. Avoid wearing shirts with pockets. Pants or Coveralls no cuffs and come over shoe tops Shoes leather, cover entire foot Gloves Leather, never use to pick up metal Safety Glasses worn under helmets and goggles and all times.

Eye Protection Wear safety glasses at all times Wear welding goggles or a face shield with a lens no. 4-6 while using torch equipment when in doubt start with too dark of a lens and then switch to a lighter one.

Color Codes Green = Oxygen Red = Acetylene

Pressure Regulating Valves Each regulator has two gauges mounted on a single manifold. One indicates cylinder pressure and the other indicates working pressure for the torch. Each regulator has an adjusting screw or T-screw, so pressure to the torch can be quickly controlled by turning the screw righty-tighty to increases pressure and left-loosey to decrease pressure.

Regulator Attachment Acetylene connectors have a V-groove left handed thread Oxygen connectors have a plain surface right handed thread

PSI Settings Acetylene = 15 psi. max Oxygen = 40 psi. max Over 15 psi. can be fatal Our regulators in the lab will be set at 7 psi. max. Oxygen = 40 psi. max Over 40 psi. will dilute the heat of the flame Our regulators in the lab will be set at 30 psi. max.

Torch Parts Torch body is the part of the torch that is held like a pencil. It contains two needle valves to control the flow of gas The welding head contains a mixer, mixing throat, and the welding tip

Types of Flames Oxidizing Neutral Excess oxygen with no feather, makes hissing sound. Sounds like an angry snake. Least used for anything Neutral Burns equal amounts of oxygen and acetylene and has a clear edged inner cone Most used

Types of Flames Carburizing Excess acetylene with an acetylene feather two to three times the length of the inner cone While burning it will produce a heavy black smoke flame Used some in hardsurfacing, adds carbon to metal

Operation Safety 1. Before you start make sure personal safety is followed. 2. Make sure you have had instruction 3. Release adjusting screw on regulators before opening valves 4. Stand on the opposite side of the regulator when opening a valve 5. Open cylinder valve slowly, oxygen first all the way open acetylene just a quarter of a turn

Operation Safety (II) 6. Do not use or compress acetylene at pressures higher than 15 psi. 7. Set working pressures as desired. Acetylene: 10 psi for NCWHS lab Oxygen: 30 psi for NCWHS lab 8. Light acetylene first 9. Never use oil on regulators or any equipment If oil mixes or touches the acetylene it will combust 10. Do not use compressed air as a substitute for oxygen 11. Keep heat, flames, and sparks away from combustibles. 12. Keep hoses out of sparks or spatter to prevent leaks

Safety Lighting the Torch Check the torch valves to make sure they are closed Open the oxygen tank valve full open Open the acetylene tank valve ¼ turn Turn on the oxygen knob on the torch body This is located next to the acetylene knob Turn the acetylene gas on no more than ¼ turn Strike and light Mix oxygen into the flame with the mixing knob on the torch body. While mixing you want to create a neutral flame. Press down on the cutting lever also to make sure the flame does not jump. The mixing knob is located half-way up the torch body next to the cutting lever

Shutting down the unit Shut down the flame by turning off the acetylene knob on the torch body. Close the oxygen mixing knob located half-way up the torch body Shut off the tanks by closing the tank valves Open the acetylene to purge or bleed the line When both gauges read zero, close the valve Open the oxygen valve Release pressure on the regulators by turning adjusting screw left or T-screw (out). DO NOT remove the T-screw Coil hoses and put tools away