Arc Welding Operations

Table of Contents

Chapter 1: Shielded Metal Arc Welding

Topics: Welding current; Arc length; Welding machines; Polarity; Tools and accessories; Electrodes; Setup and operation; Personal protection

Learning Objectives:

• Explain how the shielded metal arc welding process works.
• Tell what provides the shield in shielded metal arc welding.
• Define arc length and explain its importance.
• List factors to consider when selecting an electrode.
• Describe the personal protective equipment necessary for welding.

Chapter 2: Selecting Electrodes for SMAW

Topics: Electrode identification; Current ranges; Electrode coverings; Handling, storing, and conserving electrodes

Learning Objectives:

• Explain the factors involved in selecting SMAW electrodes.
• Explain how to identify different welding electrodes.
• Give examples of several kinds of electrode coverings and tell when each is used.
• Describe correct procedures for handling, storing, and conserving electrodes.

Chapter 3: Gas Metal Arc Welding

Topics: GMAW vs SMAW; Metal-transfer methods; Shielding gases; Electrode wire; Equipment and accessories; Gun operation; Safety

Learning Objectives:

• Name and describe the three basic types of metal transfer for GMAW.
• Name the most common shielding gases used in GMAW and tell what factors influence their selection.
• List factors that affect the selection of an electrode for GMAW.
• Describe GMAW gun operation.

Chapter 4: Gas Tungsten Arc Welding

Topics: GTAW process, equipment, current, torches, and electrodes; Shielding gases; Filler metals; Adding filler metal; Spot welding; Safety

Learning Objectives:

• List the advantages of GTAW over other welding processes.
• Describe the equipment and supplies needed for GTAW.
• Explain the purpose of the electrode in GTAW and tell how this differs from other types of welding.
• Properly select shielding gases and filler metals for GTAW.
• Describe how to use GTAW to weld common metals.

Chapter 5: Other Welding Processes

Topics: Resistance, flash, percussion, flux-cored arc, submerged arc, plasma arc, stud, electron beam, laser beam, friction, and ultrasonic welding

Learning Objectives:

• Describe resistance spot welding and resistance seam welding.
• Define flash welding, upset welding, and percussion welding, and tell how they differ.
• Explain how submerged arc welding and plasma arc welding differ from other arc welding methods.
• Describe the three forms of friction welding.
• Describe two advantages of ultrasonic welding.

Chapter 6: Preheating and Postheating

Topics: Stress; Changes in properties; When to preheat and postheat; Preheating equipment and methods; Spot preheating; Postheating methods

Learning Objectives:

• Describe the effects of uneven or rapid heating and cooling on base metals and weld beads.
• Define the heat-affected zone and tell what changes can occur there during welding.
• Explain the benefit of preheating and when it should be used.
• List several factors in welding jobs that make postheating advisable.
• Describe methods and materials for preheating and postheating.

Chapter 7: Welding Ferrous Metals

Topics: Ferrous metal identification; Edge preparation; Welding cast iron, carbon steel, and alloy steel

Learning Objectives:

• Define ferrous metals and describe their characteristics, including weldability.
• Explain cleaning and edge preparation required prior to welding ferrous metals.
• Name the welding processes and practices that are used for different types and thicknesses of ferrous metals.
• List several different electrode types and their advantages for welding ferrous metals.
• Explain specific procedures to use when welding alloy steels.

Chapter 8: Welding Nonferrous Metals

Topics: Nonferrous metal identification; Edge preparation; Cleaning; Welding aluminum, stainless steel, nickel, and copper

Learning Objectives:

• Name the special properties of several nonferrous metals and explain how these properties affect welding preparations and procedures.
• Describe some of the methods of identifying different nonferrous metals.
• Compare seven arc cutting processes used for edge preparation of nonferrous metals.
• Explain proper methods of cleaning nonferrous metals prior to welding.
• Identify the welding processes that are suitable for nonferrous metals.

Chapter 9: Pipe Welding

Topics: Piping systems and joints; Codes; Pipe materials; Repair safety; Arc, oxyfuel welding processes; Types of welding joints; Edge preparation and fitup

Learning Objectives:

• Compare the advantages of welded pipe joints to bolted or screwed connections.
• Discuss pipe welding codes and what they cover.
• List the welding processes used for joining pipe and their advantages and disadvantages.
• Identify some special methods and accessories that are used in pipe welding as opposed to flat welding.
• Give examples of the uses of preheating and postheating in pipe welding.

Chapter 10: Hard Facing and Rebuilding

Topics: Surfacing alloys; Base metals; Preheating; Surface bonding; Oxyacetylene, manual arc, and automatic hard facing; Thermal spraying

Learning Objectives:

• List several purposes of hard facing and rebuilding.
• Identify the different types of surfacing alloys and their particular uses.
• Describe effective cross-checking and explain why it is desirable.
• Explain the special techniques used in hard facing and tell why they are necessary.
• Name the welding processes used in hard facing and tell why they are adapted to this work.

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