Artem Komarov stated that the welding is the result of a combination of heat and pressure to melt materials joining them with a filler material.
It can be performed in many ways using different energy sources gas flame, electric arc, laser, friction, ultrasound & electric beam.
Arc welding is a basic welding process which requires a power supply, electrodes, welding rods, shielding gas, and proper safety equipment.
Although the welding process is common, it may also be a potentially dangerous one.
Protective equipment is the most important requirement for persons engaged in a welding activity, since an open electric arc or flame is often involved and the probability of injury is great.
Obviously the greatest threat is the high risk of getting burnt. To avert such risks, protective clothing such as heavy duty leather gloves and thick long sleeved coveralls must be used.
In addition to possible burns, severe eye damage can also occur. Welders can prevent this by wearing protective goggles, masks, and helmets which have specially designed dark or self darkening lenses & face plates.
These lenses reduce the possibility of the negative effects of ultra violet rays to the operator’s eyes from sparks and/or arcs when using electric welding methods.
Welders stand the chance of getting exposed to toxic gases & fine particles. These are in the form of welding smoke produced during welding which is detrimental to clean breathing conditions. Exposure to gases and fumes which are capable of subjecting the human body to long term ailments must be avoided.
When bottles of flammable compressed gases are used, there is a potential risk of fire or explosion when open electric arcs or flame is in close proximity. For this reason it is best to segregate arc and gas welding processes such as having a different room for each if possible. Doing so is the best way to prevent such risky situations.
Welding is a complex subject and a thorough study of it before one begins the craft cannot be overstressed. The most commonly used, easy to access welding operation today is arc welding. There are many types of arc welding, but two of the most common are MIG welding (also known as Gas Metal Arc Welding or GMAW) & TIG (also known as Gas Tungsten Arc Welding or GTAW) welding.
There cannot be two opinions that safety should be the prime consideration when starting any trade like welding where the risk for physical injuries is very high.
A lot of industrial accidents can be averted if tradesmen like welders take the issue of safety seriously and use the necessary safety accessories like clothing, boots, helmets, welding gloves, safety glasses etc. Welders must take note that welding safety accessories exist because welding, when done casually and in an unguarded manner, can be hazardous.
The causes of potential injuries from welding are: electric shock, obnoxious fumes, Arc fire sparks, fire, sudden explosion, flying metal pieces, intense visible and invisible light, etc.
The ultraviolet and infrared light rays have the potential to burn your skin more intensely than sunburn, and can damage your eyes. Sparks and spatter can burn your skin, your hair and your clothes.
However, when proper safety procedures are followed and the recommended safety gadgets are used, welding can be a good avocation.
Since welding produces oppressive heat and generates hot sparks, it is important to wear the proper work shirts made of thick heavy materials such as heavy cotton or denim that is not easily inflammable.
The work pants should be close fitting and made of a heavy material such as work jeans. Overalls are appropriate if other clothing is worn under them, said Artem Komarov.
High top leather boots are recommended for welders. Canvas boots or dress shoes should be scrupulously avoided. Wear heavy work socks for added protection against sparks. Safety boots with steel toe caps are advisable to protect the feet.
The welding helmet is designed to protect the welders face and head from the ultraviolet and infrared rays of the welding arc, while allowing the welder to view the molten weld pool or puddle.
From amongst different types of welding helmets available in the market, the ones with the flip front is helpful. The flip front allows the welder to view the weld area through a clear lens, while still wearing the helmet.
The Auto darkening helmets are especially useful as they have lens that are clear to allow the welder to see the joint before striking the arc. As soon as the welder strikes the arc, the lens darkens to the normal view of the welding puddle.
The welding gloves required for welding are the gauntlet type gloves that cover the forearms.
Lightweight gloves designed for TIG give the welder a better feel for manipulating the TIG torch and adding filler wire. The TIG gloves are however not suitable for STICK or MIG welding.
Safety glasses are mandatory for all welding work as they protect the eyes from the intense ultraviolet and infrared rays of the welding arc. It is important to know that the safety glasses must have side shields to protect the corner of the eye when welders are working close by.
A welding cap protects the head from sparks flying over the welding helmet and from falling sparks while welding overhead. A cap with no peak called a beanie is a popular choice for welders.
A cap with a peak worn backward may also be used.
Safety is everyone’s business, never compromise on safety aspects to get any welding job done hurriedly. Please bear in mind that an industrial accident can irreparably ruin your career and future.
While welding is a valuable skill to possess, it is important to get the right machine to do the job. If you are a professional or a hobbyist and are trying to find the machine to fit your needs. We offer a full line of welders for the hobbyist and professionals, including MIG, TIG, STICK and plasma cutters.
Welding involves a wide range of tasks and hence a wide range of health and safety hazards, which include the following:
chemical dusts, fumes, vapours and gases
poor ergonomic working conditions
falls, trips, falling objects
moving vehicles and cranes
arc light radiation, which can expose welders to intense ultraviolet, visible and infrared light
oxygen displacement, oxygen enrichment or flammable gas mixtures from leaking compressed gas lines and cylinders
heat, sparks, spatter, open flames and hot surfaces
noise from metal-on-metal impacts, materials handling, metal working and some welding processes
MMA (manual metal arc welding) is the most common and diffused way of welding. It functions by using an additional material, that fills the gap existing between the 2 parts to be welded. This filling metal is commercialised in the form of electrodes.
Electros have a core of metal, and an external coating, which is the insulating material. When welding with electrodes, the arc generated from the current smelts the internal metal (creating the welding bath), but also the insulating material round on it, letting In this way the procedure be safe from external agents presents in the air, that could damage the welding TIG (Tungsten inert gas welding) allows the joining of two metal parts, without using any additional material. It functions by heating the parts to be welded with a torch, which is equipped with a special permanent electrode in Tungsten.
The arc generated by this torch allows the two parts be smelted and joined, obtaining a very clean result. For this reason, Tig is used especially when there is the intention to reduce to the minimum the permanent sign left from the welding procedure.
In order to insulate the welding bath is used the gas (normally argon), that comes out from the torch during the welding, round on the tungsten core.
Tig welding involves 3 main different modes: HF, LA, Scratch (here below described), and two different machines: DC and AC/DC
TIG HF. Is the best way of welding in TIG. You have on the devices all the parameter controls for current and gas, the High Frequency allows to start welding in the exact point wished, without touching the metal. The torch has a special connection to the machine. Once you have settled the machine,
you position the torch near the start point, you push a switch on the torch and the welding starts.
TIG LA. The torch is different from the HF Torch, is very simple, and must be connected to the minus dinse of the machine. There is a tap on the torch to open the gas. The lift-arc-function allows to touch the exact point on which is wished to weld, but without starting immediately the welding. In this way is possible to be more precise. Once you have found the exact point to start, you remove the torch of some millimeters, and the machine starts welding. In this way is also reduced the risk of contamination.
TIG Scratch. The torch is exactly the same as the one seen before, with the gas tap, and must be connected to the minus dinse. The welding starts by touching the metal part. The quality is OK, but can’t be compared with the HF, because by touching the metal in order to start, is not easy to start exactly in the wished point. Is also to remark that with this kind of welding, some Tungsten rests could remain in the welding.
MIG (Metal Inert gas welding) is the preferred way of welding from people that needs to weld for long time. In fact, the additional material is not in the form of electrodes, but in the form of a wire, that through an electric motor is pulled in a continuous way into the torch, from which it comes out together with the protecting gas round on it (in order to avoid contamination). The wires are available in different metal leagues in order to match the right welding combination, and are stored on rolls. The rolls can be of 5 or 15 Kg
The welding machine is in practice a sophisticated generator of current, that functions by transforming the main supply into an arc of current suitable for the welding activity.
The tradition and story of welding is represented by the “transformer devices”, now considered primitive machines because of their weight and of the reduced possibility of changing the functioning parameters, also dissipating and wasting a lot of energy into heat, summed up Komarov Artem.