Arc Welding Introduction2

This page is INCOMPLETE and still missing some important information before it can be used as a resource. Please use the "Discussion" feature above or talk to one of the tutors if you would like to help improve it. Thanks!

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This is the content required for an introduction to our welding machines - 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 respective machine's wiki page:

• Einhell BT-GW 150 (MIG/MAG welding machine)
• Welding Transformer ("stick welding machine")

Safety

Personal protection:

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 (tip: simply wear goggles under the helmet so you can't forget them!)

Dangers	Precautions
CRITICAL HAZARD - extremely bright arc light damages eyes, risks include permanent blindness if used without appropriate protection UV radiation burns exposed skin UV can reflect off of surfaces	wear proper personal protection (see above) not all fabrics offer enough UV protection for the high doses experienced immediately stop if anything seems to be wrong with the welding helmet make sure no one else is exposed to your arc
extreme heat splattering molten metal workpiece heats up a lot welding gun and electrode (stick or wire) 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/leather 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 welding gun/electrode is hot after welding and might ignite stuff oil barrels and gas-tanks can contain explosive air fuel mixtures	know where the nearest fire extinguisher is located 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/gun only work on tanks that are definitely empty
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 even non-toxic gases can cause suffocation can accumulate in enclosed areas as most are denser than air	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 shut the gas bottle's main valve after you are done do not weld in a pit as fumes might accumulate
high pressure gas tank can explode can fall over, causing the valve to break	handle with care do not subject to heat always secure the tank so it can't fall over (e.g. chain against wall)
exposed electricity (up to 60 V DC, 150 A) still below zulässige Berührungsspannung - minor risk of shock some transformers employ a high voltage pilot arc that can jump air gaps and travel through gloves	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 when the transformer is live unplug the welding machine when not in use do not use two welding machines on the same workpiece in case of electric shock, always make sure to visit a doctor!
equipment may overheat	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 if the electrode gets stuck on the workpiece and you can't remove it quickly, turn off/disconnect the transformer and then remove the electrode and figure out better settings or switch to a new electrode
accidental/negligent arc UV light and sparks can be a dangerous surprise when not expected the trigger/pedal can be pressed by accident	wear protection prevent accidental arcs store gun/electrode on a heat resistent & electrically isolated spot unplug the welding machine when not in use
flying sharp & hot slag pieces after welding, removing slag can be dangerous	keep wearing a welding mask or safety goggles when manipulating the workpiece between welding sessions
metal dust can short the transformer	make sure the transformer does not suck up metal dust from grinding, especially the ones with active cooling

Suggested Reading

Besides these safety notes, you should read our page about welding electrodes or welding wire (depending on the machine you'll use).

These websites may also be interesting:

• BGHM: Schweißen und verwandte Verfahren (DE) - detailed safety information
• BGHM: Arbeitsschutz kompakt - Lichtbogenhandschweißen (DE) - nice short safety overview, "checklist" style
• five potentioal welding safety hazards

Demonstration

The tutor will show you these steps in detail:

• check welding helmet settings

• set up your work in the welding enclosure
  • what way to enter best
  • close gaps, e.g. with spring clamps (long-term solution needed!)
  • bring a light with you, if necessary

• turn on the BOTH exhaust systems
  • the trunk only ramps up to high if you temporarily obstruct the airflow

• gas tank settings
  • main valve
  • pressure
  • connection to transformer

• transformer & wire feeder settings
  • current adjustment
  • wire feed rate
    • always keep wire under tension (it will unravel and get tangled up like with printer filament just much worse)

• 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

• shut the gas cylinder's main valve after use