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Welding

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Learning Project Summary

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  • Project code:
  • Suggested Prerequisites: Basic understanding of metal and electricity (but not required)
    • ...
  • Time investment: approximately 275 working hours.
  • Assessment suggestions: Apprentice or Journeyman inspection.
  • Portal:
  • School:
  • Department: Technology
  • Stream
  • Level: One

Content summary

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The Welding Learning Project exists to provide a program of study and a network of feedback and support for beginning welders.

Goals

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By the time this project reaches maturity, it should:

  • describe the various processes of modern welding
  • relate essential metallurgical and technical concepts
  • prepare students to work safely in a metal shop
  • provide a course of self-study exercises that develop essential skills, harbor methodical understanding, and train ones muscles for the demanding task of joining metal
  • present comprehensive photographic and textual weld analysis tools for the independent learner
  • foster a community of mutually-supportive learners

Skills to learn include

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  • Job Safety
  • Oxy-Fuel Welding & Cutting
  • SMAW (Stick Welding)
  • GMAW (Mig Welding)
  • GTAW (Tig Welding)
  • Basic Blueprint Reading
  • Basic Metallurgy

Concerning Safety

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It is essential that Shop Safety be the first topic to be developed in this course. Welding involves bare electricity, molten metal and explosive gasses, so before any projects are attempted, the student should thoroughly understand how to interact with these elements with minimal risk.

Also, a disclaimer should be prepared and posted.

This site contains a good introduction to welding safety, including links to OSHA publications.

Learning materials

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The Internet teems with welding-related resources, and one purpose of this Learning Project is to pool them together into a useful, indexed directory.

Printed Texts

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Process Guides

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  • Oxyacetylene Welding: Basic Fundamentals by Ronald J. Baird.
  • Arc Welding: Basic Funamentals by John R. Walker
  • Flux Cored Arc Welding Handbook by William H. Minnick
  • Gas Metal Arc Welding Handbook by William H. Minnick
  • Gas Tungsten Arc Welding Handbook by William H. Minnick

Blueprint Reading

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  • Blueprint Reading for Welders (7th Ed.) by A.E. Bennett & Louis J. Siy

Metallurgy

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  • Metallurgy Fundamentals by Daniel A. Brandt & J.C. Warner
    • A basic text for beginning welders that deals almost exclusively with ferrous metallurgy.
  • Welding Metallurgy by Sindo Kou
    • An advanced text for experienced welders, or those students who have previously studied chemistry and physics.

Comprehensive Texts

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  • Welding Skills and Practices by Joseph W. Giachino & William Weeks
    • NOTE: This title is several decades out of print, but remains well worth reading for its clear and coherent discussion of both welding theory and practicalities.

Applications

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  • Welding Fabrication and Repair: Questions & Answers by Frank Marlow
    • From the Preface: "Beginning welding students learn how to make weld beads- and nothing else... [This book] goes beyond the classroom, to real life practical applications such as vehicle frame repairs, building tables, rectangular and box frames, and brackets."

The fabricated metals products compiles another group including manufacturers of pressure vessels, heat exchangers, tanks, sheet metal, prefabricated metal buildings and architectural and ornamental work. Transportation is divided into two major groups: manufacturers of transportation equipment except motor vehicles; and motor vehicles and equipment. The first includes shipbuilding, aircraft, spacecraft, and railroads. The second includes automobiles, trucks, buses, trailers, and associated equipment

Electronic Texts

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Other Internet Resources

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  • The Miller and Lincoln welding equipment companies have each prepared an impressive array of free educational materials, including how-to articles, setting calculators and interactive, flash-animated tutorials.

Introduction to the process of welding

Lessons

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  1. Introduction to the Processes of Welding
  2. General Shop Safety
  3. Math & Measurement for Welding
  4. Joint Design & Terminology
  5. Basic Welding Metallurgy
  6. Oxy-Acetylene Welding
    1. Oxy-Acetylene Equipment
      1. Cylinders
      2. Regulators
      3. Torches
      4. Filler Materials & Fluxes
      5. Other Tools
    2. Welding in the Flat Position
      1. Square (Butt) Joint w/o Filler Material
      2. Square Joint w/ Filler Rod
      3. Lap Joint
      4. T-Joint
      5. Corner Joint
      6. ...
    3. Welding in the Horizontal Position
      1. Square (Butt) Joint w/o Filler Material
      2. Square Joint w/ Filler Rod
      3. Lap Joint
      4. T-Joint
      5. Corner Joint
      6. ...
    4. Welding in the Vertical Position
      1. Square (Butt) Joint w/o Filler Material
      2. Square Joint w/ Filler Rod
      3. Lap Joint
      4. T-Joint
      5. Corner Joint
      6. ...
    5. Welding in the Overhead Position
      1. Square (Butt) Joint w/o Filler Material
      2. Square Joint w/ Filler Rod
      3. Lap Joint
      4. T-Joint
      5. Corner Joint
      6. ...
    6. ...
  7. Introduction to the Arc Welding Processes
  8. Shielded Metal Arc Welding
    1. SMAW Welding Equipment
      1. Personal Protective Equipment
      2. Welding Machines
      3. Leads
      4. Electrode Holders
      5. Ground Connections
      6. Cleaning Tools
      7. Electrodes
        1. Functions of Electrodes
        2. Electrode Identification
        3. Correct Electrode Selection
        4. Types of Electrodes
    2. Striking an Arc
    3. Running Short Beads
    4. Restarting the Arc
    5. PROJECT 1: Padding a 1/2 plate with 7018 DCRP

Assignments

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Activities

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  • Activity 1.
  • etc.

Readings

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Each activity has a suggested associated background reading selection.

References

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Additional helpful readings include:

Active participants

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Active participants in this Learning Group

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