Welding 1& 2

Google Classroom Class Code:

McCarty's Virtual classroom Link: https://pexip.me/meet/20485220

Module 1 - Safety

Students will learn safety practices about welding that will help them keep themselves along with others safe.

Lincoln Welding Safety Introductory Video

Lincoln Welding Safety Videos

Typically asked questions and answers PDF

Module 1: Q & A
Module 2: Q & A
Module 3: Q & A
Module 4: Q & A
Module 5: Q & A
Module 6: Q & A

Module 2 - Equipment

Students will be introduced to a variety of equipment that will be available for them to use in the lab. This will also cover proper use of this equipment.

Safety and General Equipment

Welding Jacket

Welding Gloves

Welding Helmet

Close Toed Shoes

Chipping Hammer

Wire Brush

Grinder

Tape Measure

Face Shield

Standard Work Gloves

Nozzle Dip

Soap Stone

Module 3 - Material Prep

Before starting any project students should prepare their materials for use. In this section we will go over how we can do that in our lab and if there might be other methods to do this.

Why do we prep our materials for use?

Welding with Aluminum?

You cannot weld aluminum with steel understanding materials and equipment will save you time and frustration while working on projects.

Weld Penetration

Weld penetration could be a result of your lack of metal preparation. If you are having trouble welding remember to think about your material prep or equipment setup. If welding on a dirty, rusty piece of metal you need to know what welding technique to use.

Choosing the right material for the job.

When you go to build something, you need to make sure that you build it to a specific standard. What does that mean?

Imagine this scenario.

A company is going to build a bridge with a capacity of 50,000 lbs. But during the construction, they wanted to save some money, so they choose to make it with a cheaper material to save on cost. As a result, the bridge now only has a capacity of 30,000 pounds. So because they decided to save money and use a different material during construction, it has resulted in a bridge that does not meet the safety standards. Unfortunately, at some point, that bridge will collapse because of the decisions made during construction.

It is better to learn how to do something correct the first time.

Measuring and cutting material

Part of preparation is cutting your materials to the correct sizes. By doing this step you it ensures that you have the right amount of material. As a fabricator it is very important to have accurate cuts.

Grinding

Cleaning a piece of metal with a grinder is an easy way to prep some materials. Often times students choose to pass over this step which results in a less than desired results.

Plasma cutter

One tool that is very handy in the metals lab is the Plasma cutter. If you can learn to cut metal accurately with this tool you will save time and money.

How to get a more accurate cut on metal

Cutting metal

Grinder Safety

Grinder

Plasma Cutter

Plasma Cutter Tips

Module 4 - Stick Welding

This will be an introduction to Stick Welding Basics. Stick welding is also known as SMAW which stands for Shielded Metal Arc Welding.

Arc Welding Equipment

Ground Clamp

Stinger

Electrodes

Portable Fume Hood

6 keys factors to successful Arc Weld

Electrode Size
Current - Set the correct voltage for the material
Polarity - AC / DC negative / DC positive
Arc Length (1/8 of an inch is the general rule for arc length) Short Arc vs. Long Arc
Electrode Angle
Travel Speed

Electrode Size

You need to make sure you have the correct electrode size for the material you are using to large of an electrode can cause excess heat in your material or to large of a weld which can cause defects later on.

Current

High Current can cause excess heat if set to high for your material.
Low Current can cause you to stick the electrode and create low penetration based on the material.

Polarity

Each electrode has specific polarities they are designed for you should always use the correct settings for the job.

Why is Arc Length important?

Arc length can be a contributing factor for creating to much heat which will effect the temperature of your metal.

Long Arc = More Heat
- - - Long Arc welds will result in a spatter look.
Short Arc = Less Heat
- - - Short Arc you have to be careful not to push the electrode through the metal.

Why is Travel Speed important?

Travel speed will help with the overall appearance of the weld along with weld penetration.

Why is the Electrode Angle important?

Angle of the electrode can be a contributing factor for weld penetration and puddle shape.

What should I set my welder to when using a 6010, 6011, 6013, 7018?

This is a great video to find out more information about electrodes and setting up your machine.

Module 3 - Stick Welding Lab Assignments

Block 6013 or 7018

300 points

3-Beads 6013, 7018, 7024

100 points

T-Single Fillet 6013, 7018

100 points each

T-Double Fillet 6013, 7018

100 points each

Square Butt Joint 6013, 7018

100 points each

V-Butt Joint 6013, 7018

100 points each

Corner Edge Joint 6013, 7018

100 points each

Corner Butt Joint 6013, 7018

100 points each

Lapp Joint 6013, 7018, 6011, 6010, 7024

100 points each

Tack Welding 6013, 7018

100 points each

Total points for Basic Stick Joint projects is 2300 points.

Polarity

AC / DC- / DC+

How do I know?

Visual Weld Inspection

How do I know if my weld is acceptable?

Plasma Cutting 101

Plasma Cutter Basics

Module 5 - MIG Welding

MIG stands for Metal Inert Gas or also known as GMAW which stands for Gas Metal Arc Welding. MIG welding shields the arc in a cloud of gas to create a cleaner weld.