1. Technology Education Dept. Bellwood-Antis High School Mr. Crowell Mr. Mackereth

2.  ARC WELDING is the melting & fusion of two pieces of base metals by the use of heat & electricity though an electrode of similar type (steel for steel, cast for cast.)  WHY IS ARC WELDING IMPORTANT?  Arc Welding allows us to construct SOLID OBJECTS out of PIECES. It replaces the need for rivets & bolts in older steel structures.

3.  ARC- the gap between the base metal and the welding electrode  BASE METAL- the two metal pieces being welded together with the arc welder  ELECTRODE- a filler metal covered with flux that is melted and mixed with base metal.  FLUX- a covering that melts & sits on the top of the weld (keeps impurities out of weld)  ARC LENGTH- distance between the electrode and the base metal. For our class, a 1/8” gap.

4.  SLAG- the excess scrap materials, molten drops, & flux that is removed after welding  CRATER (Molten Pool)-The depression that remains at the end of the weld from stopping.  BEAD- the length of welded material, usually on one piece of metal. We learn to weld beads 1 st.  BUTT JOINT- welding two pieces side by side.  LAP JOINT- welding one piece on top of another  TEE JOINT- welding two pieces perpendicular to each other (at right angles or 90 degrees.)

5.  CLOTHING  LONG SLEEVES  HAIR COVERED  LONG PANTS NO SHORTS!  SHOES & SOCKS NO FLIP FLOPS!  WELDING GLOVES  WELDING COAT or WELDING APRON  EQUIPMENT  ARC WELDER  ELECTRODE  ELECTRODE HOLDER  GROUND CLAMP  WELDING HELMET  #10 FILTER LENS  2 IN 1 CHIPPING TOOL  SAFETY SCREEN

6.  Make sure the power is OFF  Properly clothed & shielded from damage  Get metal in the proper position, select the proper amperage (GET READY FIRST!)  NO CONTACT LENSES! Glasses only!  WARN OTHERS AROUND YOU ! !

7. NNo flammable objects in the welding booth. DDO NOT LOOK INTO THE LIGHT! WWelding light is 10X stronger than sunlight! KKeep your skin covered & protected. CCool metal IMMEDIATELY after welding. MMark large objects “HOT!” with chalk.

8.  Beginning welders will use the SCRATCH METHOD. This drags the electrode across the metal surface to begin the weld.  Experienced welders will use the TAPPING METHOD. This method touches the electrode to the metal & quickly lifts the electrode up to make electric contact & strike a correct arc.  Although striking an arc by SCRATCHING is easier than TAPPING, scratching results in a poor appearance of the metal around the weld

9.  E 60 1 3  E stands for electrode  The first two #’s are the TENSILE STRENGTH  The third # is the welding position 1 is FLAT2 is VERTICAL3 is OVERHEAD  The last # is the current (AC or DC) and the depth of penetration (3 is shallow, 1 is deep)

10.  AMPERAGE SELECTION- make sure you take the time to consult the charts and select the correct electrode for the weld.  ELECTRODE ANGLE- electrodes should be at 75-80 degrees from the plane of the base metal (toward the direction of travel.)  ARC LENGTH- Arc length should be 1/8” This sounds like an egg frying in a skillet.

11.  DIRECTION OF TRAVEL- Depends on the preference of the welder ( Right vs. Left )  ELECTRODE MOVEMENT/TECHNIQUE-  Should be CIRCULAR, CONSTANT, EVEN  Use a PENCIL and NOTEBOOK PAPER.  SPEED OF WELDING- Too fast leads to a thin, weak weld, too slow results in a large welds that wastes electrodes.  NOT TOO FAST OR SLOW, JUST RIGHT!

12.  TEMPERATURE OR AMPERAGE SETTING  Thicker metal requires a higher amperage  PROPER ELECTRODE SELECTION  Improper electrodes make poor/weak welds  PREPARATION OF BASE METAL  Correct positioning makes a stronger weld  WELDING TECHNIQUE  Poor technique results in poor/weak welds