Arc Welding Introduction: Difference between revisions

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This is the content required for an introduction to our [[Welding Transformer|welding transformer]] - '''reading this does NOT replace the mandatory session with a [[tutor]]!''' It will make it a lot quicker though ;-)
This is the content required for an introduction to our [[Introduction for::Welding Transformer|welding transformer]] - '''reading this does NOT replace the mandatory session with a [[tutor]]!''' It will make it a lot quicker though ;-)
 
If you need this Introduction, please reach out to the following tutors: [[Tutor::User:Lukas|Lukas]], [[Tutor::User:Marcel|Marcel]], [[Tutor::User:Johannes|Johannes]]


Let's begin! First off, make sure you have read the machine's [[Welding Transformer|wiki page]].
Let's begin! First off, make sure you have read the machine's [[Welding Transformer|wiki page]].


== Safety ==
== Safety ==
=== Dangers ===
[[PPE|Personal protection]]: [[File:Protection - welding mask.svg|50px]] [[File:Protection - gloves.svg|50px]] [[File:protection - protective clothing.svg|50px]]
* extreme heat
 
* CRITICAL HAZARD - extreme bright arc
:Make sure you cover yourself completely, there should be no exposed skin at all!
** light damages eyes, including permanent blindness if used without appropriate protection
:*[[Welding Jacket|welding jacket]]
** UV radiation burns exposed skin
:* [[Welding Gloves|welding gloves]] over the jacket
:* ideally also a fireproof apron against molten metal drops and as additional radiation protection
:* robust shoes against glowing hot beads: sandals or sports shoes with mesh top do not provide sufficient cover
 
:'''Protect your eyes''' with a '''properly adjusted''' [[Welding Helmet|welding helmet]] during welding, and at least [[goggles]] when inspecting the weld or [[Slag Hammer|hammering]] & brushing off slag (it may be easiest to just wear goggles under the helmet so you can't forget them!)
 
{| class="wikitable"
|-
! Dangers !! Precautions
|-
| [[File:danger - optical radiation.svg|50px]] CRITICAL HAZARD - extremely bright arc
* light damages eyes, risks include permanent blindness if used without appropriate protection
* UV radiation burns exposed skin
||
* wear proper [[PPE|personal protection]] (see above)
* immediately stop if '''anything''' seems to be wrong with the welding helmet
|-
| [[File:danger - heat.svg|50px]] extreme heat
* splattering molten metal
* splattering molten metal
* sharp & hot slag pieces
* sharp & hot slag pieces
* exposed electricity (up to 60 V DC, 100+ A)
*workpiece heats up a lot
** still below ''zulässige Berührungsspannung'' - minor risk
*electrodes and other equipment also heat up
* toxic fumes (e.g. ozone, flux components, nitrous gases, heavy metal particles)
||
** galvanized steel ''(verzinkter Stahl)'' releases zinc oxide when welded which can give you "metal fume fever"<sup> [https://www.metalsupermarkets.com/welding-galvanized-steel/]</sup>
* make sure there are no gaps in your [[PPE|personal protection]], e.g. between pants and shoes or jacket and gloves
** stainless steel releases hexavalent chromium (carcinogenic)
* wear only cotton clothing - synthetics could melt to your body
** other coatings may also release all sorts of unknown compounds when vaporized
* do NOT touch hot stuff, even welding gloves just tolerate so much heat (don't ruin them) so use pliers to manipulate your workpieces if you have to
* in some cases the electrode may get stuck on the workpiece upon striking an ark
|-
** if you can't remove it from the workpiece quickly, turn off the welder and then remove the electrode
|fire hazard
** usually this can be caused if the setting on the welder is wrong or due to old electrodes


=== Precautions ===
* Sparks can ignite combustible material
* wear proper [[PPE|personal protection]]:
* workpiece can reach auto ignition temperature of its coating or residues
** cotton clothing - synthetics could melt!
* electrode is hot after welding and might ignite stuff
*** cover yourself completely, there should be no exposed skin at all
|
** [[Welding Helmet|welding helmet]] during welding, [[goggles]] when hammering & brushing off slag
* remove all easily combustible materials from your work area
** [[Welding Jacket|welding jacket]]
* make sure your workpiece is clean
** [[Welding Gloves|welding gloves]] over the jacket
* turn off the transformer and be mindful where you lay down your electrode
** ideally also a fireproof apron against molten metal drops and as additional radiation protection
* know where the nearest [[Fire Extinguisher|fire extinguisher]] is located
* immediately stop if '''anything''' seems to be wrong with the welding helmet
|-
| toxic fumes (e.g. ozone, flux components, nitrous gases, heavy metal particles)
* galvanized steel ''(verzinkter Stahl)'' releases zinc oxide when welded which can give you "metal fume fever"<sup> [https://www.metalsupermarkets.com/welding-galvanized-steel/]</sup>
* stainless steel releases hexavalent chromium (carcinogenic)
* other coatings may also release all sorts of unknown compounds when vaporized
||
* [[grind]] away '''any''' surface coatings (e.g. galvanization, paint) before welding, they could generate harmful fumes or at least obstruct your weld
* [[grind]] away '''any''' surface coatings (e.g. galvanization, paint) before welding, they could generate harmful fumes or at least obstruct your weld
* take care of good ventilation - our [[Welding Enclosure|welding enclosure]] is open at the top but that alone might not be enough for long sessions or difficult materials! Also, you should obviously avoid breathing in the fumes.
* take care of good ventilation - Use BOTH exhausts of the [[Welding Area|welding enclosure]]; but even that might not be enough for long sessions or difficult materials! Also, you should obviously avoid breathing in the fumes.
* reduce the chances of electric accidents:<sup> [https://www.bghm.de/fileadmin/user_upload/Arbeitsschuetzer/Gesetze_Vorschriften/Informationen/209_010.pdf]</sup>
* "If the air in your breathing zone is not clear, or if breathing is uncomfortable, check to be sure the ventilation equipment is working and report concerns to a supervisor" <sup> [https://www.lincolnelectric.com/en-us/support/welding-solutions/Pages/Five-potential-welding-safety-hazards.aspx]</sup>
** make sure you are isolated (proper gloves, shoes and/or floor mat) from the workpiece, especially do not touch the electrode and the workpiece simultaneously
*stop immediately if you are experiencing nausea and report the incident to a supervisor
** unplug the welding transformer when not in use
|-
** do not use two welding transformers on the same workpiece
| [[File:danger - high voltage.svg|50px]] exposed electricity (up to 60 V DC, 100+ A)
** remove the welding electrode before putting the holder down (NEVER on your workpiece or anything connected to the power!)
* still below ''zulässige Berührungsspannung'' - minor risk of shock
* equipment may overheat
|| reduce the chances of electric accidents:<sup> [https://www.bghm.de/fileadmin/user_upload/Arbeitsschuetzer/Gesetze_Vorschriften/Informationen/209_010.pdf]</sup>
* make sure you are isolated (proper dry gloves, shoes and/or floor mat) from the workpiece, especially do not touch the electrode and the workpiece simultaneously
* unplug the welding transformer when not in use
* do not use two welding transformers on the same workpiece
* remove the welding electrode before putting the holder down (NEVER on your workpiece or anything connected to the transformer!)
* if you use a cable drum, make sure to unwind it completely - a wound cable drum will induce current and heat up the cables, which may lead to a molten cable coat with high risk of a exposed mains wire
* in case of electric shock, always make sure to visit a doctor!
|-
| in some cases the electrode may get stuck on the workpiece upon striking an ark - if you can't remove it from the workpiece quickly, turn off/disconnect the transformer and '''then''' remove the electrode || use the correct setting on the transformer or switch to a new electrode
|}


== Suggested Reading ==
== Suggested Reading ==
Line 48: Line 82:
== Demonstration ==
== Demonstration ==
The tutor will show you these steps in detail:
The tutor will show you these steps in detail:
* check [[Welding Helmets|welding helmet]] settings
* set up your work in the welding enclosure
* set up your work in the welding enclosure
** red curtain far away
* turn on BOTH exhaust systems
** close gaps, e.g. with spring clamps (long-term solution needed!)
**The trunk only ramps up to high if you temporarily obstruct the airflow
** bring a light with you, if necessary
*try striking an arc and depositing metal on a scrap piece (e.g. in the shape of your initials)
* try striking an arc and depositing metal on a scrap piece (e.g. in the shape of your initials)
** it's good to experience the often scary sensation of your first arc ignition with your tutor ;-)
** it's good to experience the often scary sensation of your first arc ignition with your tutor ;-)
** once there is a steady arc, push forward and make little circles in the weld pool to "mix" the workpiece(s) with the deposited material  
** once there is a steady arc, push forward and make little circles in the weld pool to "mix" the workpiece(s) with the deposited material


{{Waiting List}}
{{Waiting List}}

Latest revision as of 13:46, 2 July 2024

This is the content required for an introduction to our welding transformer - reading this does NOT replace the mandatory session with a tutor! It will make it a lot quicker though ;-)

If you need this Introduction, please reach out to the following tutors: Lukas, Marcel, Johannes

Let's begin! First off, make sure you have read the machine's wiki page.

Safety

Personal protection: Protection - welding mask.svg Protection - gloves.svg Protection - protective clothing.svg

Make sure you cover yourself completely, there should be no exposed skin at all!
  • welding jacket
  • welding gloves over the jacket
  • ideally also a fireproof apron against molten metal drops and as additional radiation protection
  • robust shoes against glowing hot beads: sandals or sports shoes with mesh top do not provide sufficient cover
Protect your eyes with a properly adjusted welding helmet during welding, and at least goggles when inspecting the weld or hammering & brushing off slag (it may be easiest to just wear goggles under the helmet so you can't forget them!)
Dangers Precautions
Danger - optical radiation.svg CRITICAL HAZARD - extremely bright arc
  • light damages eyes, risks include permanent blindness if used without appropriate protection
  • UV radiation burns exposed skin
  • wear proper personal protection (see above)
  • immediately stop if anything seems to be wrong with the welding helmet
Danger - heat.svg extreme heat
  • splattering molten metal
  • sharp & hot slag pieces
  • workpiece heats up a lot
  • electrodes and other equipment also heat up
  • make sure there are no gaps in your personal protection, e.g. between pants and shoes or jacket and gloves
  • wear only cotton clothing - synthetics could melt to your body
  • do NOT touch hot stuff, even welding gloves just tolerate so much heat (don't ruin them) so use pliers to manipulate your workpieces if you have to
fire hazard
  • Sparks can ignite combustible material
  • workpiece can reach auto ignition temperature of its coating or residues
  • electrode is hot after welding and might ignite stuff
  • remove all easily combustible materials from your work area
  • make sure your workpiece is clean
  • turn off the transformer and be mindful where you lay down your electrode
  • know where the nearest fire extinguisher is located
toxic fumes (e.g. ozone, flux components, nitrous gases, heavy metal particles)
  • galvanized steel (verzinkter Stahl) releases zinc oxide when welded which can give you "metal fume fever" [1]
  • stainless steel releases hexavalent chromium (carcinogenic)
  • other coatings may also release all sorts of unknown compounds when vaporized
  • grind away any surface coatings (e.g. galvanization, paint) before welding, they could generate harmful fumes or at least obstruct your weld
  • take care of good ventilation - Use BOTH exhausts of the welding enclosure; but even that might not be enough for long sessions or difficult materials! Also, you should obviously avoid breathing in the fumes.
  • "If the air in your breathing zone is not clear, or if breathing is uncomfortable, check to be sure the ventilation equipment is working and report concerns to a supervisor" [2]
  • stop immediately if you are experiencing nausea and report the incident to a supervisor
Danger - high voltage.svg exposed electricity (up to 60 V DC, 100+ A)
  • still below zulässige Berührungsspannung - minor risk of shock
  • equipment may overheat
reduce the chances of electric accidents: [3]
  • make sure you are isolated (proper dry gloves, shoes and/or floor mat) from the workpiece, especially do not touch the electrode and the workpiece simultaneously
  • unplug the welding transformer when not in use
  • do not use two welding transformers on the same workpiece
  • remove the welding electrode before putting the holder down (NEVER on your workpiece or anything connected to the transformer!)
  • if you use a cable drum, make sure to unwind it completely - a wound cable drum will induce current and heat up the cables, which may lead to a molten cable coat with high risk of a exposed mains wire
  • in case of electric shock, always make sure to visit a doctor!
in some cases the electrode may get stuck on the workpiece upon striking an ark - if you can't remove it from the workpiece quickly, turn off/disconnect the transformer and then remove the electrode use the correct setting on the transformer or switch to a new electrode

Suggested Reading

Besides these safety notes, you should read our page about welding electrodes.

These websites may also be interesting:

Demonstration

The tutor will show you these steps in detail:

  • check welding helmet settings
  • set up your work in the welding enclosure
  • turn on BOTH exhaust systems
    • The trunk only ramps up to high if you temporarily obstruct the airflow
  • try striking an arc and depositing metal on a scrap piece (e.g. in the shape of your initials)
    • it's good to experience the often scary sensation of your first arc ignition with your tutor ;-)
    • once there is a steady arc, push forward and make little circles in the weld pool to "mix" the workpiece(s) with the deposited material

Waiting List

This introduction takes longer than many others and usually can't be done spontaneously during regular opening times. If you would like to receive it, please add yourself to >> this list << and we will find a good time once a few members are on it!