Level 3 Bus and Coach Engineering

Internal
Technician - (Mechelec)

Welding Safety & Fundamentals

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Internal Plant Training Academy

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Aims

• To introduce students to welding Health & Safety.

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Content Internal

• Hazards
• Safety & PPE
• Welding Terms & Fundamentals
• Welding Safety & Fundamentals
• MIG/MMA welding

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Objectives
• Students will be able to construct a risk assessment for
MIG/MMA welding tasks
• Students will be able to identify the PPE needed for
Welding tasks
• Student will be able to state welding terms
• Student will be able to identify different welding
processes and materials suitable for each process

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Practical Assessments Internal

 Conduct a risk assessment for MIG/MMA Welding

 Perform a satisfactory welded Butt joint using MIG & MMA welding equipment.

 Perform a satisfactory welded Lap joint using MIG & MMA welding equipment.

 Perform a satisfactory welded T – Fillet joint using MIG & MMA welding equipment.

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Practical Assessment 1 – Risk Assessment
Hazard Who might be harmed, and how? Sev Lik Total LMH Action to be taken When/Whom

The Risk Assessment for welding can also be used as evidence for other units

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Intro Welding (Video)

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Perform a satisfactory welded Butt joint
using MIG & MMA welding equipment

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Perform a satisfactory welded
Internal Lap joint
using MIG & MMA welding equipment

Good or Bad Weld ?

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Perform a satisfactory welded T- Fillet joint
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using MIG & MMA welding equipment

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Hazards of Welding
Hazard is something that could cause harm.
What are the hazards of welding?

What are the control measures that can be used?

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Welding Hazard Video

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Hazards of Welding Internal

Did the video cover ALL the hazards or were some missed ?
List as many hazards as you can.
UV light
Sparks
Metal Particles & Slag
Hot Metal
Electricity
Fumes
Trips
Slips
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UV Light Internal

Arc-eye, or welder's flash, is an inflammation

of the cornea caused by ultraviolet radiation.
The symptoms of arc-eye typically appear several hours after
exposure, when the eyes become red, watering and painful, often
with a gritty feeling. ‘Ghosting’ as when looking at any bright light may
also occur. The effects of arc eye are only temporary and the
symptoms generally clear up within a day or two.
As with normal sunlight, the UV light from
welding will cause reddening of the skin
(sunburn) with prolonged exposure.
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UV Light – Protection / Controls
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Ensure your eyes and face & the eyes of OTHERS are
protected

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UV Light – Protection / Controls
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Mask Types: Welding Helmet Lens

Fixed The lens shade number is often seen as the
higher the number the more protection your
eyes have. In reality good a quality welder
helmet lens will have screen filters that filter
100 percent of harmful ultraviolet (UV) and
infrared (IR) rays. So the eyes are protected
regardless of the shade number. The number
Permanently darkened. ( 10 being brighter 13 being darker) denotes
Lens can be changed for the amount of brightness or darkness while
welding.
different levels of shading

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UV Light – Protection / Controls
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Guide to lens selection

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UV Light – Protection / Controls
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Auto Darkening Helmets

An automatic welder helmet won’t darken until the weld arc is struck. High-
quality auto darkening helmets provide UV and IR protection even when the
helmet is not activated, so you are always protected, even during that split-
second before the lens darkens. These helmets generally have 3 settings:
Shade refers to the density of the darkening shield; 1 being
almost clear glass, and 10 the completely dark, unless
focused on the light of an active arc.
Sensitivity refers to the degree of light required to engage
the shade: the brighter the light, the darker the shade.
Delay refers to the speed at which the shade engages once
light is detected

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UV Light – Protection / Controls
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NOTE !!
Be careful with auto darkening masks in OUR welding
shop – check they are NOT selected to GRIND if you are
welding.

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UV Light – Protection / Controls
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Ensure all other parts of your body are protected

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Sparks

Sparks are a potential source of ignition for combustible

materials (overalls) and can also cause the welder
discomfort and inflict minor burns

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Sparks– Protection / ControlsInternal
Ensure your body and hands are protected, some welders also
wear caps to protect their head

Flame Retardant

Flame Retardant
Ensure no combustible materials are in
the welding area
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Metal Particles & Slag
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The flying sparks associated with welding are actually small

hot metal particles, furthermore with MMA welding hot
slag needs to be chipped off the weld. These particles &
slag chippings can enter the eye and cause serious damage.

Welding Chipping Hammer

or Slag Removal Pick

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Metal Particles & Slag Protection & Control

Wear eye protection EVEN THOUGH you have a welding
helmet – you lift your visor when chipping slag – so if you
are NOT wearing these….

Your eyes are NOT protected

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Hot Metal
Metal that has been subject to welding is HOT this can
cause burns if picked up. Hot metal is also an ignition
source and as such a FIRE hazard.

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Hot Metal Protection & Control
Internal

Pick up hot metal Welding gloves provide

with pliers or tongs MINIMAL protection and the
heat will be quickly transferred
to your fingers. Gloves are used
to protect from UV light &
sparks NOT to pick up hot metal

When possible
QUENCH welded
pieces

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Electricity Internal

MIG/MMA/TIG and Plasma welding all use high current electricity

to form an arc and melt the metal.
Electricity is a potential source of burns, shock & electrocution.

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Electricity Protection & Control.

Look for melted
or split cable
insulation

Check all cables for

damage before use

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Fumes
Fumes from welding can be hazardous to health aggravating
asthma and leading to more serious lung disorders
Welders have significantly higher
rates of occupational lung disease
like asthma and suffer a higher
risk of developing lung conditions
such as bronchitis and
emphysema.

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Fumes

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Fumes Protection & ControlInternal

Local Exhaust Ventilation (LEV) removes fumes from the breathing zone

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Fumes Protection & ControlInternal
As well as ventilation one of the best ways to protect from harmful
fumes is to Limit Exposure Time
HSE Guidelines set limits for how long welders are allowed to
work within an area subject to welding fumes.
• WEL - Workplace Exposure Limit.
• STEL - Short Term Exposure Limit.
• LTEL - Long Term Exposure Limit.
These vary for different welding operations

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Fumes Protection & Control

The following HSE Booklet:

EH40/2005 Workplace exposure limits

Contains a list of workplace exposure limits

for use with the Control of Substances
Hazardous to Health Regulations

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Trips
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Trips are one of the most common accidents in the workplace.

Trips in the welding shop are normally attributed to poorly placed
leads / cables.

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Trips Protection & Control
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Use cones to alert people to trailing cables.

When finished welding stow cables neatly

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Slips
Internal

Slip hazards are brought into the welding shop by the use of
dowsing buckets. Water often splashes from them onto the floor.

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Slips Protection & Control
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Mop up spillage and use safety signage

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Welding Fundamentals Internal

Definitions:
Fusion-welding uses heat to melt the base metals, a filler metal is
added to the molten pool to facilitate the process and provide bulk
and strength to the welded joint .
Total fusion - parent metal is completely melted and fused
Skin fusion - skin or surface grain structure only of the parent metal is
fused
Surface fusion - penetration is shallow forming an inter-metallic layer

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Welding Fundamentals Internal

Sections of a
GROOVE / BUTT
weld

1 Face
2 Toe
3 Root (root penetration)
4 Heat affected zone

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Welding Fundamentals Internal

Sections of a
FILLET weld

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Welding Fundamentals – Types
Internal
of Welded Joint

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The Welding Circuit Internal

Arc welding is a type of welding that uses a welding power supply to create an
electric arc between an electrode and the base material to melt the metals at the
welding point.
The term ARC welding is often, incorrectly, limited to Stick/MMA welding. But by
definition MAG/MIG (GMAW) also uses an electric arc.
The most common Welding methods are:
MMA – Manual Metal Arc or SMAW – Shielded Metal Arc Welding or Stick Welding
MIG – Metal Inert Gas, MAG – Metal Active Gas or GMAW – Gas Metal Arc Welding
Oxy – Acetylene or Gas Bottle Welding
TIG – Tungsten Inert Gas or GTAW – Gas Tungsten Arc Welding
(these will be covered in more detail in another lesson)

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The Welding Circuit Internal

Basic components:
• Welding / Torch/ Gun Cable
• Electrode Holder
• Electrode
• Welding Torch / Gun
• Electrode Wire
• Welding Unit / Power
Supply
• Return / Work Cable

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Welding Different Metals Internal

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Recommended Welding Methods for Various Metals
Welding Cutting
Stick (MMA) MIG / MAG AC TIG DC TIG Oxy Acetylene Plasma

Steel √ √ √ √ √

Stainless Steel √ √ √ √ √

Aluminium √ √ √ √

Cast Iron √ √ √

Titanium √ √

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Carbon Steel
Nearly all welding processes can be used on carbon steel
as it can handle a lot of heat.

The most common methods are MAG or MMA

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Stainless steel Internal

Stainless steel is much more prone to heat distortion and weld defects
than Carbon Steel.
Composed of steel, chromium and nickel, this alloy steel is used for
food/beverage vessels and many other products, largely because of its
anti-corrosion properties.
Stainless Steel is typically welded using MIG or TIG machines and
requires less current than carbon steel.
There are also stainless steel stick electrodes, for ARC welders. However
the base metal needs to be thick enough to stand the heat.
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Aluminium Internal

Aluminium is a non-ferrous metal, aluminium conducts heat so well that the

puddle needs to be kept constantly molten. Aluminium distorts easily if it gets
too hot.
A good TIG welding machine is the preferred method for welding aluminium.
A MIG welder (especially one with a pulse welding feature), can be used but
many wire feed mechanisms have trouble feeding the aluminium filler wire, so
a special spool feeder must also be purchased.
Although it's not the preferred choice, a stick welding machine can
also weld aluminium. Like stainless steel, the base metal must be
thick enough to stand the heat.
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Titanium, Chromoly (Chrome Alloy) and
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other Alloy Steels

Titanium - used on custom bicycles and airplanes

Chromoly - used to make strong, lightweight components for bikes,

motorcycles and automobiles. It is form of steel containing
chromium and molybdenum

These metal / alloys all have thermal sensitivity issues so they

generally require a high quality TIG machine.

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Cast Iron Internal

Cast iron cannot be forged. It is a form of iron which is poured

molten into moulds.
Cast Iron has better heat and corrosion resistance than steel and is
incredibly strong in compression. It is however, more prone to
fracturing and very difficult to weld.

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Cast Aluminium Internal

Cast aluminium is a form of aluminium

which is poured molten into moulds.
Aluminium castings are lightweight and
able to withstand the highest operating
temperatures of all die cast alloys.

Aluminium castings improve automotive fuel efficiency by

contributing to weight saving requirements
Like Cast Iron, Cast Aluminium is more difficult to weld.

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