Welding, Cutting and Brazing

29 CFR 1910.251 & 1926.350 Subpart Q & J

By: Chou Lor, Safety Coordinator

UW-Eau Claire Facilities Planning & Management

Welding, Cutting and Brazing

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
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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

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Oxygen-fuel gas welding & Cutting

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

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Oxygen-fuel gas welding and cutting

General Requirements
Focuses on using Acetylene Safely
Flammable Unstable Cannot be adjusted above 15 psi

Safe Work Practices

Blow out cylinder valve The pressure adjusting screw: Adjust the screw before Turning clockwise allows the gas allows to flow. opening the cylinder valve Turning counterclockwise reduces or stop the gas flow. Never stand in front or behind a regulator when opening the cylinder valve Open cylinder valve slowly
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Oxygen-fuel gas welding and cutting

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

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Oxygen-fuel gas welding and cutting

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

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Oxygen-fuel gas welding and cutting

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.
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Oxygen-fuel gas welding and cutting

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

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Oxygen-fuel gas welding and cutting

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.

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Oxygen-fuel gas welding and cutting

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.

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Oxygen-fuel gas welding and cutting

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.
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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

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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.
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Arc Welding & Cutting

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.Claire UW-Eau
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Arc Welding & Cutting

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.
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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.
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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
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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.
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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.
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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

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Tungsten Inert Gas Welding (TIG)

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
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Tungsten Inert Gas Welding (TIG)

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

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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 UW-Eau Claire positions

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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.
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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.

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Shielded Metal Arc Welding (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

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Shielded Metal Arc Welding (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).

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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:
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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

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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.
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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 Manufacture s specifications. Avoid electrical shock DON T wrap cables around any body part. Ensure fittings are tight.
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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 employee s DON T block your exit. Ensure that adequate ventilation and lighting are in place.
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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

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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
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Proper Ventilation for Welding

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.
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Proper Ventilation for Welding

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.

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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
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