Welding Cutting Demo

Welding, Cutting and Brazing
Research and Created by:

V. Menchavez
JWPS Journeyman Welding &
Piping Services

Training Objectives
Three Specific Types of Welding Modules

Methods of Arc Welding
Welding Hazards
Safe Work Practices
Fire Protection & Prevention
Proper Ventilation for Welding
Welding Operators Protection
Copyright Journeyman Welding & Piping Services Permission required for reproduction or display.
Three Specific Types of Welding

Modules
In this Welding, Cutting, and Brazing
module, three specific types of welding are
covered. These are listed below:
Oxygen-fuel gas welding and cutting
Arc welding and cutting
Resistance welding
Oxygen-fuel gas welding & Cutting

The elements of Oxygen-fuel gas welding
and cutting:
General Requirements
Cylinders
Service Pipe Systems
Pipe System Protection

General Requirements
Focuses on using Acetylene Safely
Flammable
Unstable
Cannot be adjusted above 15 psi
Safe Work Practices
The pressure adjusting screw:
Turning clockwise allows the gas

allows to flow.
Turning counterclockwise
reduces or stop the gas flow.
Blow out cylinder valve
Turn on cylinder valve first and

then adjust the regulator pressure screw.
Never stand in front or behind
a regulator when opening the cylinder valve
Open cylinder valve slowly

General Requirements Cont.:
Safe Work Practices
Purge oxygen and acetylene passages

Light the acetylene
Never use oil or grease
Do not use oxygen as a substitute for air
Keep your work area clean

Cylinders
Cylinder approval and marking
marked for the purpose of identifying the gas content,
with either the chemical or trade name of the gas
Storage of cylinders
Storage area must be well ventilated

Cylinders must be at least 20 feet from combustibles
Valves must be closed
Valve protection must be in place
Inside storage must be limited to 2,000 cubic feet.
Cylinders must be stored in upright position
Oxygen must be at least 20 feet from fuel gas
or 5 feet with a 1/2 hour fire barrier
Separate oxygen from fuel gas

Cylinders Cont.:
Operating Procedures
Operation must emphasize the absence
of oily or greasy substances. Follow these
rules of operation:
Cylinders, cylinder valves, couplings,
regulators, hose, and apparatus shall be kept
free from oily or greasy substances.
Oxygen cylinders or apparatus shall not be
handled with oily hands or gloves.
A jet of oxygen must never be permitted to
strike an oily surface, greasy clothes, or enter
a fuel oil or other storage tank.

Service Pipe Systems
There are special requirements for service
pipe systems when using oxygen or
acetylene.
Oxygen
Acetylene or Acetylene Compounds

Pipe System Protection
The entire service pipe system must be
protected against build-up of excessive
pressure and leaks. This protection is
accomplished with:
Protective equipment
Regulators
Proper hose and hose connections.

Pipe System Protection Cont.:
Protective equipment is divided into the two
categories listed here:
Pressure Relief Devices
The pressure relief device should discharge upwards to
a safe location.
Pressure relief valves are required in fuel-gas piping
systems to prevent excessive pressure build up within
the system.

Pipe System Protection Cont.:
Approved protective equipment shall be
installed in fuel-gas piping to prevent:
Backflow of oxygen into the fuel-gas supply
system
Passage of a flash back into the fuel-gas
supply system
Excessive back pressure of oxygen in the
fuel-gas supply system.
Arc Welding and Cutting

Definition:
A fusion process wherein the coalescence of
the metals is achieved from the heat of an
electric arc formed between an electrode and
the work.
Application
Installation
Operation & Maintenance
Arc Welding & Cutting

Application
Applies to a large and varied group of
processes that use an electric arc as the
source of heat to melt and join metals.
Installation
Arc welding requires proper installation of
equipment.
A critical part of installation is ensuring that
proper grounding is completed.

Operation & Maintenance
All connections to the machine shall be checked
to make certain that they are properly made.
The work lead shall be firmly attached to the
work.
Magnetic work clamps shall be free from
adherent metal particles of spatter on contact
surfaces.
Coiled welding cable shall be
spread out before use to avoid
serious overheating and
damage to insulation.

Operation and Maintenance Cont.:
During welding operations, cables with splices
within 10 feet (3m) of the holder shall not be
used.
Welders should not coil or loop welding
electrode cable around parts of their body.
Cables with damaged insulation or exposed
bare conductors shall be replaced.
Joining lengths of work and electrode cables
shall be done by the use of connecting means
specifically intended for that purpose.
The connecting means shall have insulation
adequate for the service conditions.
Resistance Welding
Definition:
This is a group of fusion welding processes
that use heat and pressure to make the
coalescence.
The heat comes from electrical resistance to
current flow at the site of the weld.
The processes include:

Spot Welding
Projection Welding
Seam Welding
Note: FP&M only does spot welding.
Resistance Welding
Spot Welding
A process typically used in high-volume, rapid
welding applications.
The pieces to be joined are clamped between two electrodes
under force, and an electrical current is sent through them.
The advantages of spot welding are many and

include the fact that it is:
An economical process
Adaptable to a wide variety of materials including low carbon
steel, coated steels, stainless steel, aluminum, nickel,
titanium, and copper alloys
Applicable to a variety of thicknesses
A process with short cycle times
A robust process
Tolerant to fit-up variations
Welding/Cutting Hazards
Potential Hazards
Fires may start by hot materials igniting
nearby combustibles.
Burns to the operator may occur if unprotected
skin comes into contact with the extremely hot
work.
Magnetic fields could easily
destroy/disrupt electronic
components, stored data if
not careful.
Welding/Cutting Hazards
Potential Hazards Cont.:
Metal fumes from vaporizing of the work with the
extremely hot arcs may be inhaled into the workers
lungs.
Certain metals and metal oxide fumes, including zinc,
cadmium and beryllium, produce serious illnesses
when inhaled.
Fluxes used with welding to create inert atmospheres
at the point of the weld also present inhalation
hazards.
All welding and cutting must have adequate
ventilation to protect the person doing the welding
and those working around the welding area.
Methods of Arc Welding

Three Types of Welding Methods:
Tungsten Inert Gas Welding (TIG)
Gas Metal Arc Welding (MIG)
Shielded Metal Arc Welding (SMAW)/ Stick
Welding

Definition:
TIG welding is an arc that is formed

between a non-consumable tungsten
electrode and the metal being welded.
Gas is fed through the torch to shield the
electrode and molten weld pool.
Benefits:
Welds with or without filler metal

Precise control of welding
variables (heat)
Low distortion
Shielding Gases:
Argon
2 to 5% Hydrogen
w/Helium

Applications
Most commonly used for aluminum and
stainless steel
For steel
Slower and more costly than consumable
welding
Except for thin sections or where very high
quality is needed
Gas Metal Arc Welding (MIG)

Definition:
The heat source is formed by creating an
electric arc between the work piece and a wire,
which is fed continuously into the weld pool.
Benefits:
Long welds can be made

without starts and stops
Minimal skill required
Minimal cleaning of
surface before weld
Allows welding in all
positions
Gas Metal Arc Welding (MIG) Cont.

Shielding Gases:
Inert
Argon, Helium
Used for aluminum alloys and stainless steels.
Active
1 to 5% Oxygen, 3 to 25% CO2
Used for low and medium carbon steels
Applications
Gas Metal Arc Welding (MIG) is used to weld all
commercially important metals, including steel,
aluminum, copper, and stainless steel.
Shielded Metal Arc Welding

(SMAW)/Stick Welding
Definition:
Consumable electrode coated with
chemicals that provide flux and shielding
The filler metal (here the consumable
electrode) is usually very
close in composition to
the metal being welded.

(SMAW)/Stick Welding
Benefits
Simple, portable,& inexpensive
Self flux provided by electrode
Provides all position flexibility
Shielding Gases
No shield gases added
Lower sensitivity to Wind

(SMAW)/Stick Welding Cont.:
Applications
Construction, pipelines, shipbuilding,
fabrication job shops.
Used for: Steels, stainless steels, cast irons.
Not used for aluminum and its alloys, or
copper and its alloys (energy density is too
high).
Cutting
Definition:
A stream of oxygen is directed against a piece of
heated metal, causing the metal to oxidize or burn
away.
Making a Cut
Mark a line as a guide.

Turn on acetylene as for welding and light.
Turn on oxygen adjusting flame to neutral.
Make sure the oxygen lever flame remains neutral.
Place metal on the cutting table so metal will fall
clear.
Flame Types:
UW-Eau Claire
Facilities
Planning
Management
Copyright Journeyman Welding
& Piping
Services&
Permission
required for reproduction or display.
Brazing
Definition:
A process which a filler metal is placed at or between
the faying surfaces, the temperature is raised high
enough to melt the filler metal but not the base metal.
The molten metal fills the spaces by capillary attraction.
Torch Brazing
Oxy-fuel torch with a carburizing flame
First heat the joint then add the filler metal
Safe Work Practices

Electric & Gas Welding
Safety Check:
Ensure electrical cord, electrode holder
and cables are free from defects
No cable splices within 10 feet of electrode holder.
Ensure welding unit is properly grounded.
This helps to avoid over heating.
All defective equipment shall be repaired

or replaced before using.
Safe Work Practices

Electric & Gas Welding Cont.:
Safety Check:
Remove all jewelry rings, watches, bracelets,

etc
Ensure PPE e.g.. welding hood, gloves, rubber
boots or safety shoes, apron are available and in
good condition.
Ensure fire extinguisher is charged and available.
Ensure adequate ventilation and lighting is in place.
Set Voltage Regulator to Manufactures
specifications.
Avoid electrical shock DONT wrap cables around
any body part.
Ensure fittings are tight.
Safe Work Practices

Electric & Gas Welding Cont.:
Safety Check:
Inspect hoses for cuts and frayed areas.
Set gauges to desired PSI.
Ensure that sufficient PPE is made
available.
Locate welding screens to protect
employees DONT block your exit.
Ensure that adequate ventilation and
lighting are in place.
Fire Protection & Prevention

Fire hazards must be removed, or
Guards installed, or
Welding/cutting must NOT take place
Hot work permit should be used

outside designated areas to ensure
that all fire hazards are controlled
Use of fire watch
1/2 hour after operation ceases
Fire Protection & Prevention Cont.:

Welding areas should meet the following
requirements:
Floors swept & cleared of combustibles 35 ft.
radius of work area.
Flammable and combustible liquids kept 35 ft.
radius of work area.
At least one fire extinguisher on site
Protective dividers to contain sparks
and
slag
Welding curtains
Non-combustible walls
Fire resistant tarps & blankets

Ventilation
Proper ventilation can be obtained either naturally or
mechanically.
Natural Ventilation is considered sufficient for welding and
brazing operations if the present work area meets these
requirements:
Space of more than 10,000 square feet is provided per welder
A ceiling height of more than 16 feet.
Mechanical ventilation options generally fall into two basic

categories.
Low vacuum system which takes large volumes of air at low
velocities.
High vacuum system that are captured and extracted fumes as
near to the work as possible.

Ensure protection from fumes
and gases by one or a
combination of the following:
Good general ventilation.
Use of a booth.
Local exhaust ventilation
on the hand piece.
Air supply to the helmet.
Welding Operators Protection

Welding involves specialized personal
protection that must be worn every time
you perform welding operations. The
following is a list of basic PPE:
Fire-resistant gloves
Aprons
Safety shoes
Helmet
Ultraviolet radiation filter plate (arc welding)
Goggles with filter lenses

Summary
Major hazards include:
Fire
Burns
Shock
Toxic Exposure
Follow proper procedures to prevent fires

Use appropriate engineering controls
Wear appropriate PPE
Any Questions
??

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Welding, Cutting and Brazing

Research and Created by:

Welding, Cutting and Brazing

Three Specific Types of Welding Modules

Three Specific Types of Welding

Oxygen-fuel gas welding & Cutting

Oxygen-fuel gas welding and cutting

Safe Work Practices

The pressure adjusting screw:

Turning clockwise allows the gas

Blow out cylinder valve

Turn on cylinder valve first and

Oxygen-fuel gas welding and cutting

Purge oxygen and acetylene passages

Oxygen-fuel gas welding and cutting

Storage area must be well ventilated

Oxygen-fuel gas welding and cutting

Oxygen-fuel gas welding and cutting

Oxygen-fuel gas welding and cutting

Oxygen-fuel gas welding and cutting

Oxygen-fuel gas welding and cutting

Arc Welding and Cutting

Arc Welding & Cutting

Arc Welding & Cutting

Arc Welding & Cutting

The processes include:

The advantages of spot welding are many and

Methods of Arc Welding

Tungsten Inert Gas Welding (TIG)

TIG welding is an arc that is formed

Welds with or without filler metal

Tungsten Inert Gas Welding (TIG)

Gas Metal Arc Welding (MIG)

Long welds can be made

Gas Metal Arc Welding (MIG) Cont.

Used for low and medium carbon steels

Shielded Metal Arc Welding

Shielded Metal Arc Welding

Shielded Metal Arc Welding

Mark a line as a guide.

Safe Work Practices

Ensure welding unit is properly grounded.

This helps to avoid over heating.

All defective equipment shall be repaired

Safe Work Practices

Remove all jewelry rings, watches, bracelets,

Safe Work Practices

Fire Protection & Prevention

Hot work permit should be used

Fire Protection & Prevention Cont.:

Proper Ventilation for Welding

Mechanical ventilation options generally fall into two basic

Proper Ventilation for Welding

Welding Operators Protection

Welding, Cutting and Brazing

Follow proper procedures to prevent fires

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