Instructor's Guide

Instructor’s Guide

Welding Processes and Fundamentals Series Gas Tungsten Arc Welding (GTAW)

Introduction This guide provides information to help you get the most out of the Shopware Gas Tungsten Arc Welding program of the Welding Processes and Fundamentals series. As the title suggests, Gas Tungsten Arc Welding introduces this popular fabrication and repair process, covers the basic setup procedures involved, and illustrates basic welding techniques. This video program also describes the potential dangers that gas tungsten arc welding poses, along with the steps you should take to ensure welding safety.

Learning Objectives After viewing the program, students will be able to:

• Understand how gas tungsten arc welding (GTAW) systems work.

• Identify the potential dangers welding presents to trade professionals.

• Understand how a GTAW system is set up for use.

• Understand how GTAW systems are used for repair and fabrication.

• Understand how to troubleshoot GTAW welding problems.

43939 Gas Tungsten Arc Welding (GTAW) Instructor’s Guide

Program Overview This program is designed to give viewers a foundation in gas tungsten arc welding (GTAW) systems, their setup, and their proper use. Sections 1 and 2 of this program introduce the GTAW process and examine the physical components of a typical GTAW system. The selection and preparation of the tungsten electrode is especially important when using GTAW systems and Section 3 covers this in detail. In Section 4, a comprehensive discussion of personal protective equipment (PPE), such as appropriate helmets, gloves, and clothing, is undertaken. The following Sections 5 through 8 cover the setup of a typical GTAW system and proper techniques that students should know when welding. In particular, students are shown the attributes of high-quality welds and how welding technique can influence the process. Also shown are several different arrangements of the base metals being joined, the terminology that is used to describe them, and the types of welding beads and passes that are most appropriate for each. The Gas Tungsten Arc Welding program ends in Section 9 with a short conclusion and words of encouragement for student welders. Correlates to all National CTE Organizational Standards (including the provisions of the Perkins Act).

Main Topics Section 1: Introduction to Gas Tungsten Arc Welding This section introduces the viewer to gas tungsten arc welding (GTAW) and explains how the electric arc between the nonconsumable electrode and base metal creates a molten pool to which the welder adds filler metal in order to join the base metals together. This segment also explains the value of using an inert shielding gas to protect the molten weld puddle from atmospheric contamination.

Section 2: Components of a Gas Tungsten Arc Welding System Here, viewers learn about the technology and use of typical GTAW systems and practical consid- erations when using them. Students learn about the GTAW welder, DC/AC power, details on the filler wire used, the shielding gases employed, grounding clamps and other components. Covered in detail is the construction of the welding torch and how its various components are cleaned and assembled for use.

Section 3: Selecting and Preparing the GTAW Electrode Section 3 covers the proper selection and preparation of the GTAW electrode. Details such as matching the diameter of the electrode to the base metal thickness and American Welding System (AWS) electrode classifications are discussed. Because the quality of the electric arc is directly af- fected by the shape and condition of the electrode tip, details on dressing and shaping tips before use are covered.

43939 Gas Tungsten Arc Welding (GTAW) Instructor’s Guide

Section 4: Safe Welding Environment and Protective Equipment This section covers the steps necessary to ensure that the welding environment is safe for the welder and others in the work area. This segment also introduces the student to the personal protective equipment (PPE) that should be worn whenever cutting or welding is practiced. It is noted that some PPE items used for GTAW may vary from those used in other welding processes.

Section 5: Setting Up a Gas Tungsten Arc Welding System for Use This section goes through the step-by-step process of setting up a GTAW system for use. Discussed is the careful examination of equipment before use, the proper settings on the GTAW welding equipment and the preparation of the welding tip on the welding torch. Students are advised that a methodical step-by-step process is the best way to perform a system setup.

Section 6: Laying a Bead Section 6 goes through the process of creating high-quality welds with GTAW equipment. In the trade, this is often referred to as “laying a bead.” The many details that student welders should know when welding and laying beads are covered. This includes details such as the preparation of the base metal and guidelines for adding filler metal. Special emphasis is paid to the best two-hand techniques to use when holding the welding torch and how the proper traveling motion of the gun and arc can be used to create high-quality welds.

Section 7: Advanced Welding Techniques Welders must join pieces of metal in many different configurations and alignments. Each of these generally requires a specific approach for high-quality welds. Topics such as root passes, fill passes, and horizontal, vertical, and overhead locations are covered. The very important concept of tacking the project together in preparation for welding is also covered.

Section 8: Reading the Bead Good welders must be able to look at welds and beads and judge their quality. When welds are created that are of poor quality, welders must know the parameters that caused this, such as voltage, travel speed, gas pressure, etc., as such parameters can be quickly be adjusted or changed. Special emphasis is paid to monitoring the welding process and what steps to take if anomalies affecting the weld occur during the process. Examples of this include too much spatter, porosity, poor penetration, and wavy beads.

Section 9: Troubleshooting This closing section shares safety tips for all trade professionals involved in GTAW along with wishes for continued success in the subject area.

43939 Gas Tungsten Arc Welding (GTAW) Instructor’s Guide

Fast Facts • Although GTAW is more difficult to learn, it offers the operator greater control over the welding process than competing procedures such as SMAW and GMAW, allowing for stron- ger, higher-quality welds.

• GTAW is considered the best method with which to weld stainless steel and aluminum metals, especially thin sheets, by most fabricators. Fabrication engineers prefer GTAW welds because of their low-hydrogen properties and the close match of mechanical and chemical properties with the base materials.

• One of the best practices to prevent injuries is to wear personal protective equipment (PPE) whenever welding or cutting. Those who disregard this practice subject themselves to unnecessary risk.

• Gas tungsten arc welding (GTAW) can be used to weld not only ferrous metals but also difficult-to-weld metals such as alloys and aluminum.

• The Occupational Safety and Health Administration (OSHA), of the U.S. Department of Labor, states that welding, cutting, and brazing are hazardous activities posing safety and health risks to more than 500,000 workers in a wide variety of industries.

• The GTAW process can produce temperatures of up to 35000 degrees F, in contrast, the average temperature of the Sun’s surface is 9900 degrees F.

• The brightness and danger of the light emitted during welding and cutting varies with the type of metal being welded and the welding process utilized. If skin is exposed to intense ra- diation energy, such as that from an electric arc, it can result in skin burns, premature aging, and ultimately skin cancer.

• Gas tungsten arc welding (GTAW) is very sensitive to the condition of the base metals. Common contaminants such as corrosion, oil, paint, and galvanization must be removed via brushes, abrasives, sand blasting, etc.

• Many cutting and welding processes produce toxic fumes: gases and airborne particulates that can be harmful if inhaled. Welders and cutters should not disregard the danger of these fumes.

• Oily rags in the welding environment can be a danger even at great distances. Sparks can travel 20–30 feet and smolder in oily rags for hours before actual combustion (flames) occurs.

43939 Gas Tungsten Arc Welding (GTAW) Instructor’s Guide

Vocabulary Terms Amperage–The amount of current flowing in a circuit, which is measured in amperes.

Argon–An inactive gas commonly used as shielding. Argon is heavier than air, so it effectively shields the weld area.

Autogenous Welds–Welds that are made without filler rod.

Backhand Technique–Moving the electrode along the workpiece opposite the direction of the welding bead.

Combustible–A substance that readily ignites and burns when exposed to flames and sparks.

Confined Space Permit–A special permit issued by safety organizations such as OSHA that specify the requirements that must be met in order for welding or other processes to be executed in a “confined space.”

Constant Voltage–Welding using a voltage that varies slightly with changes in current. Con- stant voltage (CV) is often used for gas tungsten arc welding (GTAW) and flux-cored arc welding (FCAW).

DCEP–An abbreviation for direct current electrode positive. DCEP is another way of expressing direct current reverse polarity (DCRP).

DCRP–Acronym for direct current reverse polarity.

Duty Cycle–The term duty cycle refers to the amount of time during a 10-minute period that a piece of welding equipment can be used. For example, the Miller Thunderbolt XL creates a 200 amp DC output at 20 percent duty cycle. This means it can weld continuously at 200 amps for two minutes and then must cool for eight minutes to prevent overheating.

Filler Rod–A metal rod that is used to add metal during the welding process.

Fill Pass–After the first welding pass (the root pass) is performed in a deep weld, the subsequent passes are often referred to as fill passes. This is because they essentially provide the “fill” for the rest of the weld.

Forehand Technique–Moving the electrode along the workpiece in the direction of the welding bead.

43939 Gas Tungsten Arc Welding (GTAW) Instructor’s Guide

GTAW–Acronym for gas tungsten arc welding.

Inert Gas–A nonreactive gas used during cutting and welding to shield molten metals from external contaminants.

Oxidized–Oxidation is the process whereby oxygen combines with a metal surface and a new com- pound is created. In the case of iron and steel, oxidation creates iron oxide, which is most commonly called rust. Most metals oxidize to some degree, with iron and steel doing so relatively quickly.

Particulates–Tiny particles of solid or liquid matter suspended in a gas or liquid. In welding and cutting, particulates are often emitted and tend to be hazardous to breathe.

Porosity–Cavity-type discontinuities or bubbles formed by gas entrapment during solidification of the weld metal. Porous welds are considered low-quality welds, and welders should be familiar with the various factors that can lead to them.

PPE–Acronym for personal protective equipment, which refers to professional welding helmets, gloves, boots, and other appropriate clothing and gear that is used when welding and cutting.

Purge–In welding parlance, “purging” means allowing all the gas to escape from pressured hoses.

Regulator–The valve apparatus typically installed on the top of gas tanks that is designed to meter gases for welding and cutting use.

Root Pass–A root pass is usually the first welding pass that is taken in a large weld. After the root pass has been accomplished, filler welds are typically laid on top.

Shielding Gas–An inert or semi-inert gas used in many welding processes. Inert gases are generally used to shield molten metals so that atmospheric contaminants do not enter.

Spatter–Under certain conditions, arc welding scatters out tiny droplets of molten steel. These metal droplets are messy and dangerous. Spatter also creates rough and unsightly welds that are very difficult and time-consuming to clean.

Stick-out–A term used to describe electrode extension, or the distance from the end of the contact tip to the end of the electrode.

Tacking–Tacking is a process whereby the pieces of metal that are to be fastened together are welded in a number of small places along the full welding path. This process holds the entire structure steady and in the correct dimensional form during the full welding process.

43939 Gas Tungsten Arc Welding (GTAW) Instructor’s Guide

Tie-in–The term used for restarting a weld so that it is continuous. This is an important concept because welds that are paused for any reason must be tied in properly or the weld quality can be compromised.

Torch–The electrode holder in GTAW systems.

Tungsten–An element (atomic number 74) that is metallic and melts at a very high temperature (6192 degrees F).

Pre-Program Discussion Questions 1. What exactly is welding? What are welders trying to accomplish? 2. Are there different ways to weld metals? Explain and describe at least one method that you know about. 3. What is gas tungsten arc welding (GTAW)? How does it work? 4. Why is it so important to understand the risks and take proper precautions when using GTAW equipment? 5. GTAW generally requires a shielding gas. Why is this? 6. How can most of the risk of injury be eliminated? 7. Which trade professionals are likely to perform GTAW? 8. What are the different types of welds that welders may be called upon to perform? 9. What types of dangers might welders experience on the job beyond those of dealing with the welding equipment itself (e.g., the welding environment, confined spaces, standing water)?

Post-Program Discussion Questions 1. In basic terms, describe how a GTAW system works. 2. Describe the various types of personal protective equipment (PPE) that welders would use. 3. Is inspecting the welding equipment before using absolutely necessary? Why? 4. What types of metals can be welded with GTAW systems? 5. How important is the condition of the base metals in GTAW? How can you clean them? 6. What are the basic steps to setting up a GTAW system for use? 7. How does a welder know what settings to use initially when setting up a GTAW system? 8. Why is the shape and condition of the tungsten electrode so important? 9. In what ways does OSHA protect welders and cutters on the job? Why are these workplace regulations important? 10. Describe the differences between using forehand and backhand methods when laying beads with GTAW. 11. Describe the process of adding the filler rod to the molten pool during GTAW. 12. What kinds of problems might a welder see with GTAW weld quality? What would one do to correct them?

43939 Gas Tungsten Arc Welding (GTAW) Instructor’s Guide

Suggested Student Projects • Trade Professions Involving Welding Instruct students to research a variety of specific trade professions that involve welding. Each student selects one profession to research in order to learn how welding is used in this specific trade—and writes a one-page description. The class can then compile the descriptions into a vocational handbook. This handbook can be converted into PDF form and made downloadable on the school website.

• A Pictorial View of Welding Safety Practices Students review welding safety images found on the Internet and then create posters illustrat- ing and spelling out the safety tips involved in the trade. The posters might be created for workplace safety, a training program, or as a checklist for trade professionals as they gear up for a job. Alternatively the images can be compiled into a PowerPoint presentation for class use.

• Welding Safety Training Students work in small groups to create short “safety training classes” that welding professionals might attend. Encourage students to use a variety of presentation techniques (visuals, props, role plays, dramatization, etc.). The sessions can be captured on video and uploaded to YouTube.

• Face-to-Face To learn more about welding, students can interview various trade professionals who either work as welders or have welding and cutting as part of their work. These interviews can be shared with the class in the form of a report or PowerPoint presentation or can even be video-captured for YouTube.

• Guest Lecturing Students can arrange for trade professionals to visit the classroom and discuss the welding trade. Professionals can be asked what they like about the trade and exciting projects they may have worked on. They can also be encouraged to share specific experiences with the class, such as situations “when things went wrong.”

43939 Gas Tungsten Arc Welding (GTAW) Instructor’s Guide

Assessment Questions Q1: Gas tungsten arc welding is often referred to as: a) Stick welding b) GTAW c) TIG welding d) Both a) and b) e) Both b) and c)

Q2: The inert gas that is released during GTAW does what? a) Cools the weld quickly b) Keeps air away from the weld puddle c) Quiets the noisy welding process d) Both a) and b)

Q3: Which article of PPE (personal protective equipment) is the least significant to consider when welding or cutting metals? a) Long-sleeved cotton shirts and pants with no cuffs b) Gauntlet-style leather gloves c) Extra-thick helmets to protect the welder from concussions d) Steel-toed work boots e) Professional welding jacket

43939 Gas Tungsten Arc Welding (GTAW) Instructor’s Guide

Q7: What are the advantages of using a GTAW system? a) Few sparks are generated b) Little smoke and slag is produced c) It is excellent for thin metals d) All of the above

Q8: Cleaning the base metals in preparation for welding may involve: a) Wire brushing b) Muriatic acid c) Abrasive sanding e) Sand blasting f) All of the above

Q11: If a GTAW weld is showing excessive “spatter,” what do you do? a) Slow down the electrode gun travel b) Reduce the machine voltage c) Increase the gas pressure d) All of the above

43939 Gas Tungsten Arc Welding (GTAW) Instructor’s Guide

Assessment Questions Answer Key Q1: Gas tungsten arc welding is often referred to as: a) Stick welding b) GTAW c) TIG welding d) Both a) and b) e) Both b) and c) Answer: e) When gas tungsten arc welding was first developed, it was called tungsten inert gas welding, or TIG welding. The American Welding Society broadened the term some time ago to gas tungsten arc welding or GTAW. Today we use both TIG and GTAW, but GTAW is the preferred version.

Q2: The inert gas that is released during GTAW does what? a) Cools the weld quickly b) Keeps air away from the weld puddle c) Quiets the noisy welding process d) Both a) and b) Answer: b) Atmospheric air is composed of approximately 21 percent oxygen. Oxygen is a highly reactive element and is capable of combining with most other elements. The primary function of gas shielding is to keep atmospheric oxygen away from the molten metal. The gases used to do this are inert gases such as argon, carbon dioxide, and others.

Q3: Which article of PPE (personal protective equipment) is the least significant to consider when welding or cutting metals? a) Long-sleeved cotton shirts and pants with cuffs b) Gauntlet-style leather gloves c) Extra-thick helmets to protect the welder from concussions d) Steel-toed work boots e) Professional welding jacket Answer: c) This question is designed to allow the instructor to review the topic of PPE (personal protective equipment) with students. The many potential hazards of welding and cutting can be mitigated by use of the proper PPE at all times. This means long-sleeved cotton shirts and pants with no cuffs, leather welding gloves, professionally designed welding helmets (either auto-darkening or with a selection of welding filters), rugged work boots (preferably steel-toed), and a professional welding jacket. The “least significant” item is arguably c). Welding helmets are not primarily designed to prevent welders from accidental blows due to falling debris and other objects. They are specifically designed to protect the welder’s eyes from the intensity of the electric welding arc, and the flesh on the welder’s head and neck from the IR/UV rays that are emitted during welding.

43939 Gas Tungsten Arc Welding (GTAW) Instructor’s Guide

Q4: Which activity is least important for ensuring a safe welding environment? a) Maintaining good ventilation b) Ensuring room light switches are easy to access c) Eliminating paper, rags, and other combastible debris nearby d) Clearing the floor and welding structure (bench, tables) of unnecessary cables and hoses Answer: b) This question is designed to allow the instructor to review the topic of hazards in the welding environment. Clearing hazards from the welding area can mitigate the many potential dangers of welding and cutting. General hazards include paper, rags, and other combustibles, while tripping hazards include hoses, cables, and metal parts. In addition, when using electric tools such as arc welders and plasma cutters, moisture and standing water must be avoided. It is also important to maintain good ventilation of the welding environment, especially in confined areas.

Q5: Why is the shape and condition of the tungsten electrode so important? a) It can affect the weld quality b) It helps you see the welding process better c) It can affect the behavior of the arc d) Both a) and c) Answer: d) The shape and condition of the tungsten electrode can have a dramatic effect on how the electric arc behaves. With poorly shaped electrodes, the electric arc can shift around during welding and this can affect the quality of the weld being created.

Q6: There are many settings on a GTAW system. Parameters such as voltage, current polarity, wire speed, and gas volume must all be adjusted according to the welding job. These settings should come from: a) Your classmates b) Manufacturer’s recommendations c) Charts on the welding machine d) Your welding instructor only e) Both b) and c) Answer: e) There are many parameters that need to be set on a GTAW system before use. The manufacturers of the various consumables and equipment will usually provide documentation that can assist with these settings. In addition, most manufacturers of the GTAW machines have a permanent label on those machines that give suggested settings for various applications.

43939 Gas Tungsten Arc Welding (GTAW) Instructor’s Guide

Q7: What are the advantages of using a GTAW system? a) Few sparks are generated b) Little smoke and slag is produced c) It is excellent for thin metals d) All of the above Answer: d) This question is designed to allow the instructor to review the topic of the advantages of using GTAW systems. There are many. In GTAW, very little smoke is produced and few sparks are emitted. Additionally, because the operator can control the arc current, it is an excellent way to weld thin metals. The disadvantage of GTAW systems is that they can be a little harder to learn and are more expensive to use.

Q8: Cleaning the base metals in preparation for welding may involve: a) Wire brushing b) Muriatic acid c) Abrasive sanding d) Sand blasting e) Only a) and c) f) All of the above Answer: f) The condition of the base metals when performing GTAW is quite important. Mechanical methods of exposing clean base metals are common, as are chemical methods such as using muriatic and other acids.

Q9: Protecting against welding-generated toxic fumes is important because: a) Breathing toxic fumes can affect your welding technique b) Toxic fumes can cause short-term health problems c) Toxic fumes can cause long-term health problems d) Both b) and c) e) All of the above Answer: d) Workers should consider the type of base metal that is being welded or cut, e.g., iron, steel, aluminum, or zinc. They should also know about any coatings on the base metal, like zinc on steel for rust protection. When heated during welding and cutting, materials can be burnt or vaporized. This may create toxic fumes, which can cause short- and long-term heath effects. Workers should always verify that plenty of ventilation exists whenever welding or cutting is practiced.

43939 Gas Tungsten Arc Welding (GTAW) Instructor’s Guide

Q10: Forehand welding refers to a method of welding whereby: a) The welder “pushes” the puddle b) The electrode gun is held like a tennis racket c) The welder “drags” the puddle d) Both a) and c) Answer: a) Forehand welding is a technique whereby the welder leans the welding gun slightly backward and “pushes” the molten puddle along. Forehand welding typically generates less heat in the base metal and thus less penetration than other techniques.

Q11: If a GTAW weld is showing excessive “spatter,” what do you do? a) Slow down the electrode gun travel b) Reduce the machine voltage c) Increase the gas pressure d) All of the above Answer: d) Each of the listed parameters affects the quality of the weld in a way that can contribute to excessive spatter. It is important to recognize when spatter is occurring during welding and to take immediate action. Spattering not only presents a safety hazard; it is also poor welding technique that is difficult to clean after the welds are completed.

Q12: Why is it especially important to cover all exposed flesh when arc welding? a) Hot sparks can tickle when they strike you b) It will shield your skin from infrared (IR) light c) It will shield your skin from ultraviolet (UV) light d) Both b) and c) Answer: d) Arc welding creates a very powerful light source that can emit not only visible light but also IR and UV rays. UV rays in particular are damaging to skin tissues and can create painful “sunburn” to exposed flesh.

43939 Gas Tungsten Arc Welding (GTAW) Instructor’s Guide

Additional Resources American Welding Society–www.aws.org/technical/facts The American Welding Society (AWS), founded in 1919, is a nonprofit organization with a goal to advance the science and technology of welding and related joining disciplines. Their website offers a great deal of welding safety and instructional material.

Lincoln Electric–http://www.lincolnelectric.com/en-us/support/Pages/resources.aspx In business over 115 years, Lincoln Electric is one of the world’s foremost welding equipment and supply companies. They have an extensive library of resources for welders of varied experience, from seasoned professionals to students learning the trade.

Miller Welding–www.millerwelds.com/resources/resources Miller is one of the largest manufacturers of welding and cutting equipment and has an extensive collection of online resources for welders at all stages in their careers.

NASD: National Ag Safety Database–http://nasdonline.org The National Ag Safety Database (NASD) is a collection of publications about agricultural safety and health. NASD contains many kinds of informational materials, including fact sheets, training materials, PowerPoint presentations, video references, and complete online videos. Search on “welding safety.”

United States Department of Labor, Occupational Safety and Health Administration– http://www.osha.gov/SLTC/weldingcuttingbrazing/index.html Created by Congress in 1970, the Occupational Safety and Health Administration (OSHA) assures safe and healthful working conditions for working men and women by setting and enforcing standards and by providing training, outreach, education, and assistance. They have an extensive collection of welding safety documents and forms.

Weld Guru–www.weldguru.com Weld Guru is a private site designed to aggregate content related to welding and cutting. Many helpful, informative, and easy-to-read documents can be found here.

Welding Information Center–www.weldinginfocenter.org The Welding Information Center is a website sponsored by current and former manufacturers and distributors of welding rods. The purpose of the site is to educate the public by gathering and providing access in one place to notable publications, articles, and other materials.

43939 Gas Tungsten Arc Welding (GTAW) Instructor’s Guide

Additional Resources at www.shopware-usa.com Shielded Metal Arc Welding (SMAW) Often referred to as “stick welding,” SMAW has been used for decades to weld most metals and alloys. This video helps students learn the basics of the SMAW method, in which the electrode is con- sumable and becomes part of the weld. Identifying critical system components, the video explains different power types and power levels and includes a discussion of DCRP, DCSP, and AC modes. It then shows how to choose the correct welding rod, make sure that all equipment and working conditions meet professional safety standards, set up the system to begin work, correctly lay a bead, and read or inspect a bead. A segment on advanced techniques looks at several types of joints—edge, corner, lap, and tee joints as well as various butt joints—in addition to root, fill, and cap passes. Solving the problem of arc blow is also covered. Correlates to all National CTE Organizational Standards (including the provisions of the Perkins Act). A viewable/printable instructor’s guide is available online. A Shopware Production. A part of the series Welding Processes and Fundamentals. (23 minutes)

Gas Metal Arc Welding (GMAW) Also referred to as MIG (metal inert gas) welding, GMAW creates an arc with a solid wire fed through an MIG gun and melted to form a weld. This video guides students through the basics of gas metal arc welding, which is often used in automotive, structural, and production manufacturing. Helping students identify the correct duty cycle for the job at hand, the video explains the function and specifications of the electrode, or filler wire, as well as the other GMAW tool components. Safety, transfer modes, general set-up procedures, laying and reading beads, and other topics are featured. A troubleshooting segment helps deal with problems like an erratic puddle, excessive spatter, porosity, poor penetration, and excessive penetration, with advanced GMAW techniques also explored. Correlates to all National CTE Organizational Standards (including the provisions of the Perkins Act). A viewable/printable instructor’s guide is available online. A Shopware Production. A part of the series Welding Processes and Fundamentals. (23 minutes)

43939 Gas Tungsten Arc Welding (GTAW) Instructor’s Guide

Oxy-fuel and Plasma Cutting Preparing for a welding project usually involves cutting metal into specific shapes and pieces, a task that requires many of the same tools and know-how used in welding. This video serves as a basic guide to two popular heat-based cutting methods: oxy-fuel and plasma. Beginning with an overview of safety procedures, the video shows how to set up an oxy-acetylene system and demonstrates correct coupling distance, travel speed, torch angle, machine finishing, and other aspects of handheld cutting. Additional fuel choices are listed, too. The plasma segment includes a basic definition of what plasma is and how it can be cut. Viewers learn the fine points of setting up and cutting with a plasma system and are given numerous tips and guidelines, from one- and two-hand torch ma- nipulation to troubleshooting various problems. Correlates to all National CTE Organizational Standards (including the provisions of the Perkins Act). A viewable/printable instructor’s guide is available online. A Shopware Production. A part of the series Welding Processes and Fundamentals. (28 minutes)

Welding Safety This video covers the most important safety rules and protective equipment to use when performing MIG, TIG, arc, and gas welding. Welding helmets and their lens ratings, leather aprons and gloves, welding gas respirators, heat shields, and fire extinguishers are discussed, and various types of welders, including plasma cutters, are illustrated. Correlates to all National CTE Organizational Standards (including the provisions of the Perkins Act). A viewable/printable instructor’s guide is available online. A Shopware Production. Part 2 of the Safety and Technology Series. (22 minutes)

Tools of the Trade: Inside the Welder’s Toolbox This program shows viewers the safe way to work with fire, gas, and molten metal as it profiles the tools used by welders to perform a variety of tasks. Specific tools and equipment for OFW, GMAW, GTAW, and SMAW are spotlighted, along with a variety of general tools and safety items. The video also takes a look at basic welding diagrams and pre-welding treatment of materials. A viewable/ printable instructor’s guide is available online. A Shopware Production. (23 minutes)

43939 Gas Tungsten Arc Welding (GTAW) Instructor’s Guide

Welding: Auto Body Repair This video puts safety first as it explains how to use an MIG (GMAW) welder. Weld types, welder setup, destructive tests, and general welding techniques are covered. The causes of contact burnback, incomplete fusion, and other problems are identified. A viewable/printable instructor’s guide is available online. A Shopware Production. (23 minutes)

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