A Specialist Rank Project

Written by: CFC Luke Wills

Texas 6th Charlie

May 2012

Table of Contents

Introduction 3

Welding Equipment 5

Additional Accessories 7

Hazards 8

Safety Equipment 9

Preparation 12

Welding 15

Reorganization 18

Conclusion 19

Acknowledgments 20

Introduction

What is Shielded Metal Arc Welding?

Welding in its most simplified form is the fusion of metal pieces. The temperature of the metal is heated to such a high degree that the metal being welded melts into liquid in order to fuse together. There are many different types of the same action of welding; forge welding, oxyacetylene welding (more commonly known as gas welding), laser welding, electron beam welding, explosive welding, ultra sonic welding, friction welding, and arc welding to name a few.

Arc welding is defined as welding that uses a power supply to direct an electric arc in order to form a molten pool of metal at the welding point. There are many different types of arc welding such as gas tungsten (more commonly known as TIG), gas metal (more commonly known as MIG), flux-cored, submerged, plasma, and shielded metal.

Shielded metal arc welding is the technical name that the American Welding Society gave what is more commonly known as stick welding. This is one of the oldest, simplest, and most multipurpose welding methods. It uses a consumable electrode that is coated with a dry chemical called flux. While welding, the flux is burnt off the electrode at the welding point and shields the metal from atmospheric contaminates. The flux then cools and hardens to form slag. Slag is a layer of porous, brittle metal formed from the residue of flux that coats the top of the weld.

What is the purpose of welding?

Welding is used for three main purposes; to fix broken gear, to construct both useful equipment and metal art, and to strengthen weak areas or areas that are subject to constant friction.

Why should I learn about welding?

Luke 16:10-11 “He that is faithful in that which is least is faithful also in much: and he that is unjust in the least is unjust also in much. If therefore ye have not been faithful in the unrighteous mammon, who will commit to your trust the true riches?” Welding is a good way to practice being faithful with what we have been given. Instead of throwing a broken tool or piece of equipment away and buying a new one, you could fix it by welding and still continue using it long after its life expectancy. In Matthew 25 Jesus tells a parable about three servants who were put in charge of different amounts of the master’s money. The two that doubled the amount they were given, were praise by their master in verses 21 & 23 “…Well done, good and faithful (servants); thou hast been faithful over a few things, I will make thee ruler over many things: enter thou into the joy of thy lord.” The servant who just hid the money was called “wicked and slothful” (verse 26) and his portion was given to one of the other faithful servants. One definition of the character quality of resourcefulness is: Making wise use of that which others would overlook or discard. Welding is an excellent way to practically demonstrate Resourcefulness while being faithful with what you are given as well.

3 What will I learn about welding in this document?

You will learn about the different parts to a stick welder and how it works, the equipment you will need to safely operate a stick welder, the hazards, safety precautions, and a process of how to weld from start to finish.

4 Welding Equipment

Parts of a welding machine

The welding machine has five parts: the power supply, the ground clamp, the electrode holder, the electrode, and the leads.

The power supply is the box shape part of the machine that regulates the electrical power from either an electrical outlet or a gas generator.

The ground clamp is a clamp that is clamped to either the metal you are welding on, or the metal that the metal you are welding on is clamped to.

The electrode holder has a simple definition; it is a clamp that holds the electrode.

The electrode is a rod coated with a dry chemical called flux.

The leads are the wires connecting the ground clamp and the electrode holder to the power supply.

The path of electricity through a welding machine

Electricity flows into the power supply from either an electrical outlet or a gas generator. It then goes out through the electrode lead and electrode holder to the electrode itself. The small space that is between the tip of the electrode and the piece of metal that is being welded is traversed by electricity forming an arc. It continues its path through the ground lead and the power supply where it finishes by going into the ground.

5 Other welding tools

Though the welding machine is a must have, these other items are crucial for good welds.

Chipping Hammer

A chipping hammer is used to break off the large pieces of slag that normally form on the top of each weld from the melting flux.

Wire Brush

A wire brush is used to clean the weld from small pieces of slag that the hammer can’t get to. It can also be used to clean off dirt and rust on the metal to be welded in order to obtain a better weld.

Clamps

In order to keep the metal you are welding stationary, clamps are employed. There are many different types of clamps are used such as; c-clamps, locking pliers, and table-mounted vises.

6 Additional Accessories

Wire Wheel

An electric powered wire wheel is very useful for cleaning off multiple welds or preparing a large surface for welding. It can also shine the finished weld and give the metal a cleaner look.

Grinding Wheel

An electric powered grinding wheel is useful for grinding down welds in order to reweld or in order to add another weld on top of it. It can also polish the finished weld and give the metal a metallic look.

7 Hazards

Clutter

Clutter is defined as anything that hinders your speed, productivity, or compromises your safety while welding. Flammables such as paint & gas cans, an oxyacetylene torch, paper, and leaves should all be swept or moved away. Sharp edges, tangled leads, and unnecessary tools, etc… should all be moved, or picked up and stored in their proper place.

Temperature

The tip of the electrode can get 4 to 20 times hotter than the maximum temperature of a common household oven. The temperature of the arc can be anywhere between 2,500 ° F and 10,000° F. Skin, clothing, plastic, leather, wood, and other materials will burn if in contact with that amount of heat for most any period of time more than a brief brush.

Light

The light that is emitted by the arc contains harmful Ultra-violet (UV) rays which can burn the corneas of your eyes. Looking directly at a welding arc with little or no protection can cause what is commonly called arc eye or corneal flash burn. The medical term is photokeratitis and its symptoms are a feeling of small glass pieces or sand in your eyes. If prolonged eye exposure to the arc occurs without adequate protection, permanent blindness or black spots in your vision may result due to the burning of the retina.

Fumes

While the flux on the electrode provides a shield of gas around the arc to keep it from atmospheric contaminates, it also emits a chemical that is poisonous at higher concentrations and after being constantly inhaled over a longer period of time.

Sparks & Flying Pieces of Metal

Sparks and flying pieces of metal are hazards for more than one reason. The sparks may splatter in or near flammables such as aerosol cans, grass, paint cans, leaves, and gas cans. They also will sting and can severely burn any exposed skin. The most sensitive part of your body to sparks and flying pieces of metal (such as slag and rust from prepping for or cleaning a weld) are your eyes. Slag is lightweight with a potential of flying a long distance.

8 Safety Equipment

Welding Personal Protection Equipment (PPE)

Welding Shield

A welding shield (more commonly known as a helmet) is the most crucial part in a welder’s PPE. It protects the face and eyes from sparks and can reduce the amount of fumes that is inhaled by a welder. The average entry-level helmet is made out of nylon has a filter lens that is interchangeable. Some other helmets are made out of NORYL, leather, and fiberglass and many have special features such as an auto-darkening lens or a flip front.

Welding Gauntlets

Since your hands are the closest to the arc welding gauntlets (more commonly known as gloves) are necessary to keep your hands protected. Most are made from leather and will absorb some of the heat from the arc and metal that you are working with. Always retire or patch gloves that have holes in them. Also make sure that the gloves are not wet or sweaty since they can then become a conductor of electricity.

Safety Glasses or Face Shield

It is very important that you protect your eyes even after you have finish welding. The slag that builds up on a weld has a tendency to ping off as the metal contracts and cools. Some welders will wear safety glasses under their welding helmet in case a stray spark ends up on the inside. This also eliminates having to keep track of where you put and the constant process of having to take them on and off.

9

Proper Welding Clothing

The proper welding attire is crucial for your health and safety. Leather aprons, jackets, and chaps will give the most protection but can be beyond your budget. If that is the case you can use denim or just plain cotton, long-sleeved work shirts and pants as a substitute. Steer clear of synthetic and man-made materials since most will melt when burning rather than smoldering. Try to avoid using shirts that have pockets and pants that have cuffs as they can collect burning red-hot sparks. Keep away from clothing that is frayed or have holes in them as they will ignite easier.

Make sure that your shirt is clasped as close to your neck to keep sparks from finding their way down into your shirt. Always keep your pants over the top of your shoes in order to keep sparks and slag from going between your shoes and feet.

Some welders wear a welding cap under their helmet in order to keep stray sparks from burning their hair. A cost effective substitute is a baseball cap with the bill facing backwards or a beanie.

Proper Welding Footwear

The most protective type of footwear is leather, high-topped, steel-toed, bottom-plated boots. However if your money is tight, regular work shoes can be used but extra precautions must be taken. If they are not leather or high-topped, place a piece of fire resistant cloth (such as leather) over the top of them. If they are not steel-toed or bottom plated you take the risk of burning or crushing your feet if something hot is stepped on or something heavy dropped.

Fire Extinguisher

While welding it is an absolute must to know the location of the fire extinguisher and how to safely use it. A multipurpose extinguisher that is rated for solid combustibles, liquid & gas, and electrical fires is

10 normally used since it is less likely to increase the destruction of the fire by putting the wrong type of extinguisher on the fire.

Ear protection

Ear plugs or muffs are used both to dampen noise and to protect your ear canal from flying sparks. If you are in a busy, noisy shop with other people, ear protection will allow your ears to hear healthier longer. Also on average sparks won’t fly into the ear canal unless the welding point is eye level or above.

Welding Curtains and Screens

As a responsible welder you should not only be concerned about your safety, but also the safety of those around you. See-through welding curtains and screens will protect against shooting sparks, flying metal, and most will block some or all of the UV light waves. A less expensive option is a thick tarp or canvas.

11 Preparation

Choosing the Right Amperage

Amperage is the measure of the strength of an electrical current. Most welding machines have a setting that adjusts the amperage. Never change the amperage while you are welding as this could cause internal damage to the welding machine. The correct amount of amperage usually depends on the type of metal you are using and the type, brand, and thickness of the electrodes. Normally the thicker the metal the more amperage you will need. The correct amperage setting is important to a good weld with maximum penetration. One way to determine the correct amperage is to weld a single pass welding deposit (or more commonly known as a bead) about 2 inches long on a scrap piece of metal. If the slag comes off easily while you are chipping and there is minimal spatter (extra round-shaped metal that gets stuck to your project), then you know that the welder amperage setting is close to the correct setting for that type of metal. If not, adjust the settings until there is easy slag removal and minimal spatter.

Electrode

Table Thickness of Metal being welded Normal AMP Range Electrode Diameter

Up to 3/16 inch 20-40 1/16 inch

Up to 1/4 inch 40-125 3/32 inch

Over 1/8 inch 75-185 1/8 inch

Over 1/4 inch 105-250 5/32 inch

Over 3/8 inch 140-305 3/16 inch

Over 3/8 inch 210-430 1/4 inch

Over 1/2 inch 275-450 5/16 inch

12 Picking the Right Electrode

There are many different types and thickness of electrodes. Generally the thicker the metal to be welded, the thicker the electrode you will need. These are some basic guidelines to the identification of electrodes marked by the American Welding Society’s classification system.

• The letter “E” at the beginning denotes that it is an electrode as opposed to rod or flux. • The first two numbers in a four digit number and the first three digits in a five digit number indicates the electrode’s minimum tensile strength in kilo-pounds per square inch (ksi). Tensile strength is the measure of the ability of a material to withstand a force of stress attempting to tear the material apart. • The next to last number indicates the positions that this electrode can be used in. o 1 Flat, Horizontal, Vertical (moving up), & Overhead o 2 Flat & Horizontal o 3 Flat o 4 Flat, Horizontal, Vertical (moving down), & Overhead • The last two numbers together signifies the chemical coating and type of current that can be used with the electrode.

Here is an example of the American Welding Society’s classification system.

E6011

E This is an Electrode

60 Its tensile strength is a minimum of 60 ksi (or 60,000 pounds per square inch [psi])

1 it can be used in most welding positions

11 it has a high cellulose potassium coating that uses both AC & DC currents. This allows the electrode to work well with dirty, rusted, or painted metals with a high penetration.

Here are two of the more common electrodes and the types of metal they are used for:

E6013 This electrode can be used with AC & DC currents but it has medium penetration with a superior weld bead appearance.

E7018 This electrode is an all-position, low-hydrogen electrode. It also can be used with AC & DC currents that can produce x-ray quality welds with medium penetration.

13 Also talk with your local welding supply dealer for their suggestions on the electrode that should be used for the type and thickness of metal you want to weld.

Selecting the Right type of Current

With some types of welding machine you have the option to adjust the electrical current. The current is the way that electricity flows through a circuit. There are two main ways in welding that a current flows: Direct Current (DC) and Alternating Current (AC). Direct Current has two polarities that the current flows: DC Positive (+) and DC Negative (-). DC+ heats up the electrode and sends the flow of electricity into the metal from the electrode. This will gives less penetration and is good for thin metals. DC- heats up the metal and sends the flow of electricity into the electrode from the metal. This flow of electricity will produce more penetration and is good for thick metals. AC is just what it says it is, a current that alternates back and forth from positive to negative. The continuous change of polarity cleans the weld and helps to shield the weld from oxide.

Practicing Striking an Arc

Striking an arc is one of the parts of welding that takes some time to get used to doing. If you have never welded before you might first try to practice striking an arc without the machine being on. You want the electrode to hit the metal and then pull back to about 1/8th inch away from the surface of the metal. Get a feel for having a steady hand and only coming enough off the metal to maintain the arc.

If you bring the electrode too close to the metal you are welding on, it will fuse itself to the metal. When this happens, quickly move the electrode holder in a side-to-side motion. This action will break the bond in order for you to continue welding.

Safety Precautions

These are some basic safety tips that are a good thing to get into a habit of doing whenever you are about to start welding.

Look around the welding area (a 10 or 20 foot radius) for any hazards such as clutter or standing water. Make sure you have plenty of air circulation and can easily access the correct type of fire extinguisher. Confirm that all your PPE is in place and welding curtains or screens are set up to keep bystanders from getting burned from the light. Now you’re ready to do some actual welding!

14 Welding

The Setup

1.1 Before you even power up the welding machine decide what you are going to weld and how. This will determine whether you need to cut, grind, or wire brush your project. Also make sure the metal you will be welding on is stabilized and will not move while you are working with it. If it is not, secure it with clamps or in a vise. 1.2 Check the On-Off switch and make sure it is in the off position. 1.3 Plug in the machine to the wall outlet if electric powered or fire up the generator if it is gas powered. Be careful not to get your fingers (or anything else for that matter) between the prongs of the electrical plug while plugging or unplugging the welding machine. 1.4 Unwind the leads and attach the ground clamp to a point on the metal that you will be working with (you also can attach the ground clamp to a piece of metal that the piece you are working on is clamped, bolted, or welded to). Make sure the attach point is relatively clean from dirt, rust, and paint. You may have to use the wire brush to make a clean spot. 1.5 Clamp the chosen electrode into its holder. 1.6 After confirming that there is no way electricity can flow from one lead into the other, turn on the machine. 1.7 Hold the electrode holder in your dominate hand by your side. 1.8 Shout “Helmets down.” This is not common in a welding shop but is a safe habit to get into. It lets those around you know that you are about to start welding. If they want to watch you, and have all their PPE on properly, it is a command to put their helmet down. If they are doing something else, it is a reminder not to look over in you direction since you will be welding. 1.9 Double check that those watching you have there helmets down, and those that don’t have their helmets down are turned completely away from you. Remember it is the welder’s responsibility to look out for the safety of himself and those around him. 1.10 Bring the electrode close to where you want to weld and flip your helmet down.

15 The Weld

2.1 Begin welding by striking an arc. The two most common ways are strike method and the tap method. For the strike method, use the electrode like a match and drag it across the metal producing a lot of sparks and spatter. After this is done a couple of times start welding by

striking one more time but this time end the strike by coming up to about the length of the diameter of the electrode, away from the metal. The tap method takes a lot more practice but it does not leave as much spatter and cleaning of the weld afterwards. Tap the electrode to the metal and quickly bring it back up to about the diameter of the electrode, away from the metal. 2.2 After you have struck an arc, lay a welding bead by angling the electrode 45* towards your dominate hand and slowly dragging the electrode in the direction of your dominate hand and away from your body. Some welders like to make tiny circles as they weld a bead. Your speed across the metal should be steady and continuous. Watch the molten pool; for most flat welds it should stay round or slightly oval. If it looks like it is a river then you are probably going too fast. Also if the metal around the weld is getting white-hot than you might be going too slowly. 2.3 Remember since you are welding with a consumable electrode your electrode will be getting shorter so you will have to keep adjusting your hand for a good arc height. Make sure that the tip of the electrode stays relatively close to the metal. One way to check is to listen to the arc. The sound you are listening for is a sharp crackling sound. If the sound is hollow then you are most likely too far away from the metal. If the sound is more of a sizzle then you are probably too close. 2.4 After you are done with the weld, bring your electrode up out of the weld quickly to break the arc and not to leave excess spatter on the metal that you will have to clean up later.

16 2.5 Bring your helmet up and shout “Helmets Up” this command will signal those nearby that you are done welding until you give another “Helmets Down” command. 2.6 If you need to weld again on top of a previous weld make sure to chip and brush off as much of the slag that you can get to. This gives less of a possibility of slag becoming trapped in the weld and weakening it.

The Clean Up

3.1 Turn off the welding machine. 3.2 Remove the used electrode from its holder.

A used electrode will be extremely hot!

3.3 Unplug the machine. Be careful not to get your fingers (or anything else for that matter) between the prongs of the electrical plug while plugging or unplugging the welding machine. 3.4 Untangle and wrap the leads in loose coils.

17 Reorganization

Set all the welding tools back where they belong. Place any cooled, unused metal back where you got it and any scrap metal into a scrap-metal bin. This will allow you to find the piece that you need when you go to look for it. Brush any loose pieces of metal or slag into a metal trashcan only used for metal pieces. Do not use a regular plastic can or one that has flammables in it; they may catch fire or melt. Put away all your tools into their proper place and sweep up any dirt or metal from off the ground. This allows you to be more productive the next time and reflects your character by demonstrating responsibility and orderliness.

18 Conclusion

It is my prayer that God has used this report to “spark” an interest in the broad field of welding. Be faithful, resourceful, and creative as you weld, remembering that, “He that is faithful in that which is least is faithful also in much…” (Luke 16:10a). I hope that you will seek out and find a skilled welder with lots of experience. Ask lots of questions, and be safe. Happy Arcing!

Soli Deo gloria. Glory to God alone!

19 Acknowledgements

I give God all the honor and glory for this project. He has given me a safe welding experience so far, and the strength and energy to stay up late into the night in order to complete this project.

Special thanks to;

My Dad, 2Lt. Lee Wills for constantly driving me to and from the welding class and for assisting me when I was behind on my welding projects.

My Mom, for continuously encouraging me to finish this specialist project, and for driving me to class the days that Dad couldn’t make it.

My welding instructor Cadet Father Roger Daniels for being patient with my multitude of questions, his wife Linda for taking some of the pictures, and his son LTC Cody Daniels for being a role model as to how to weld and help others learn how to weld.

My little sister Anna for being my welding partner these past few years. She has always given me good competition, and has kept me scrambling to weld just a little bit better than her.

My youngest sister Melody for always being enthusiastic with the many different projects that Anna and I made.

My older sister Carrie for her encouraging words of how grateful she is that God gave her me as a younger brother.

My safety advisor WO Randy Isitt for being there to give me tips on how I could work safely while still accomplishing a lot of work and for carpooling with my family as we went to welding class. Also, his son LTC Paul Isitt for assisting me with the unit demonstration and some of the pictures in this report.

The ALERT Cadet Unit Texas 6th Charlie for being attentive and cooperative while I gave the unit demonstration.

The International ALERT Academy for letting me use their welding shop when I gave the unit demonstration.

All those who helped proof read and edit this report.

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