The process of working with metals to
create individual parts, assemblies, or
large-scale structures. The term covers a
wide range of work from large ships and
bridges to precise engine parts and delicate
jewelry.
It
therefore
includes
a
correspondingly wide range of skills,
processes, and tools.
DIFFERENT SHAPES OF MATERIALS
FIRE PROTECTION
FIRE – is a constant danger during welding or cutting.
Highly combustible materials should be 35 ft.(10.7 m) or more away
from any welding.
FIRE WATCH – can be provided by any person who knows how to
sound the alarm and use a fire extinguisher.
TYPE OF FIRE EXTINGUISHERS
TYPE A Used to extinguish combustible solids(PAPER, WOOD & CLOTH).
The symbol is a green triangle with the letter A in the center.
TYPE B Used to extinguish combustible liquids(OIL, GAS & PAINT THINNER). The
symbol is a red square with the letter B in the center.
TYPE C Used to extinguish electrical fires(MOTOR, FUSE BOXES & WELDING
MACHINE). The symbol is a blue triangle with the letter C in the
center.
TYPE D Used to extinguish combustible metals(ZINC, MAGNESIUM &
TITANIUM). The symbol is a yellow star with the letter D in the
center.
LOCATION OF FIRE EXTINGUISHERS
The locations of fire extinguishers should be marked with red paint
and signs high enough so that their location can be seen from a distance
over people and equipment. The extinguishers should also be marked
near the floor so that they can be found even if a room is full of smoke.
Mount the fire extinguisher from 1 m to 1.5 m so that it can be
lifted easily in an emergency.
HOW TO USE FIRE EXTINGUISHERS?
P
Pull
the
pin.
A
S Aim low at the base of
the
fire.
S
Squeeze the handle.
Sweep side to side.
5’S POLICY WORK PRACTICES
1. SORT(Seiri)
Discard the unnecessary things for effective space utilization.
2. SWEEP(Seiso)
Keep work bench, floor, tools, machine free from all dirt, oil
stain, chips and dust.
3. SANITIZE(Seiketsu)
Keep the work place free from dust particles, smoke, bad odor,
acid or alcoholic vapor and gas by good air conditioning.
4. SYSTEMATIZE(Seiton)
Keep anything available when necessary by standard
partitioning rack, accommodation loading and unloading,
colors and labels for maximum efficiency.
5. SELF DISCIPLINE(Shitsuke)
Let us accomplish and observe what has been decided
upon about machine handling, work standard, inspection
and maintenance procedure, lubrication and reporting.
Metals contain iron.
FERROUS METAL
NON-FERROUS METAL Are those metal which do not
contain iron.
EXAMPLE OF FEROUS METAL
Pure iron
Wrought iron
Cast iron
White cast iron
Malleable cast iron
Gray cast iron
Steel
EXAMPLE OF NON-FEROUS METAL
Gold
Silver
Aluminum
Nickel
Tin
Lead
Copper
Chromium
Tungsten
Platinum
Monel metal
Muntz’ metal
PROPERTIES OF METALS:
MALLEABILITY - Quality of being hammered and
flattened into thin sheets without breaking.
DUCTILITY -Allows a metal to be drawn out into fine
wires w/o breaking.
HARDNESS - Enables a metal to resist force w/o
changing its shape.
ELASTICITY - Enables a metal to return to its original
shape after bending and pulling it out of
shape.
BRITTLENESS - Makes a metal breaks easily.
FUSIBILITY - Melts a metal easily & is usually
combined w/ other metals to make an alloy.
MEASURING TOOLS
MEASURING TOOLS
MEASURING TOOLS
MEASURING TOOLS
MEASURING TOOLS
MEASURING TOOLS
CUTTING TOOLS
CUTTING TOOLS
CUTTING TOOLS
CUTTING TOOLS
CUTTING TOOLS
CUTTING TOOLS
CUTTING TOOLS
CUTTING TOOLS
CUTTING TOOLS
CUTTING TOOLS
CUTTING TOOLS
CUTTING TOOLS
CUTTING TOOLS
CUTTING TOOLS
CUTTING TOOLS
CUTTING TOOLS
DRIVING TOOLS
DRIVING TOOLS
DRIVING TOOLS
DRIVING TOOLS
DRIVING TOOLS
DRIVING TOOLS
DRIVING TOOLS
HOLDING TOOLS
HOLDING TOOLS
HOLDING TOOLS
HOLDING TOOLS
HOLDING TOOLS
HOLDING TOOLS
HOLDING TOOLS
HOLDING TOOLS
HOLDING TOOLS
HOLDING TOOLS
HOLDING TOOLS
The inch is divided into segments
called graduations. Each graduations
represents a measurements in form of a
proper fraction. The inch can be divided
into 2, 4, 8, 16, 32, etc., equal parts.
Reading a Ruler
Standard
(inches)
Metric (centimeters/millimeters)
Standard (inches) measurements are
read and written as fractions.
Metric (centimeters/millimeters)
measurements are read and written
as decimals.
Reading a Standard Ruler
1/8
1/4
1/2
Units
__ __ __ __ __ __ __
__
__ __
__
0
1
1/8
1/4
1/2
Units 0
__ __ __ __ __ __
__
__
__
__
1
1/8
1/4
1/2
Units 0
__ __ __ __ __ __ __
__
__
__
__
1
1/8
1/4
1/2
Units 0
__ __ __ __ __ __ __
__
__
__
1
3 15/16
2 3/16
1 7/32
1/16
3 11/32
7 23/32
5 7/32
4 3/16
6 1/16
9 1/16
• Reading a Metric Ruler
55 1/4
56 13/32 in.
73 3/8 in.
201 9/16 in.
81 11/32
2. 56 13/32
56x32+13 in. X .0254 m
=
1 in.
32
.0254 m
1805
=
X
1
32
=
45.847m
= 1.432719 m.
32
2.54 m
1 in.
2.54 m
1490.98m
587
=
=
X
=
1
8
s18
186.3725 m.
5. 201 9/16 in. = 201x16+9 in. X 2.54 m
16
1 in.
3225 25.4 mm 81915mm
=
=
X
=
1
16
16
5119.6875 mm.
3. 73 3/8 in. = 73x8+3
8
in. X
152.2 cm.
119.1 cm.
6. 119.1 cm. = 119.1 cm. X
194.3 cm.
206.9 cm.
119.1 in.
1 in.
=
2.54
2.54 cm.
= 46.8898 in.
7. 152.2 cm. = 1.522 m.
8. 194.3 cm. = 1.943 dm.
9. 206.9 cm. = .2069 dm.
10. 582.4 cm. = 582.4 cm. X
582.4 in.
1 in.
= 229.291 in.
=
2.54
2.54 cm.
582.4 cm.
The metric system uses prefixes added
to the base unit to represent larger or
smaller units. Each prefix is a multiple
of 10.
Prefix
Abbreviation Word value
Number
value
kilo
km
one thousand
1000
hecto
hm
one hundred
100
deka
dam
ten
10
deci
dm
one tenth
0.1
centi
cm
0.01
milli
mm
one
hundredth
one
thousandth
0.001
The process of joining metal pieces by heating them to
suitable temperature that would cause them to melt and
fuse together into a single piece.
This may be done with or without the application of
pressure and with or without the use of a filler metal in
the composition and melting point of the base metals
being joined.
COMMON KINDS OF WELDING
COMMON KINDS OF WELDING
TYPES OF WELDING MACHINE
1. AC WELDING MACHINE
A welding machine that uses
alternating current as power
supply.
2. DC WELDING
MACHINE
A welding machine that uses
direct current as power supply.
3. AC-DC ARC WELDING
A welding machine that uses both
MACHINE
AC and DC as power supply.
4. DIESEL OR GASOLINE ENGINE
DRIVEN DC OR AC WELDING
A welding machine driven by diesel
MACHINE
or gasoline through a generator
used where there are no power
lines especially in remote areas.
PROPERLY DRESSED WELDER FOR PERSONAL
PROTECTION
Personal Protective Equipment (PPE)
The observation of health and safety
precautions in welding operation is of greatest
importance. Your life and that of the others are
more important than the job you are doing.
1. Welding shield/helmet
Used to protect our face and eyes from the arc
rays and heat, and the spatter from molten metal.
The arc is viewed through a filter which reduces the
intensity of radiation but allows a safe amount of
light to pass for viewing the weld pool and end of
the electrode.
1.1 Helmet type welding shield is more
convenient to use because it allows both hands to
work freely.
1.2 Hand-held shield allows only one hand to
work freely.
2. Leather jacket
Made of chrome leather and prevents the entry
of sparks between our clothes and body.
3. Leather apron
Made of chrome leather and provides a welder
with complete protection of his chest to mid calf
from sparks and hot metal.
4. Welding gloves/gauntlet
Made of chrome leather and protects our
hands from heat, spatter, and radiations.
5. Face shield
Best for general protection because it can be
worn under an arc welding helmet.
6. Leggings
Made from leather to protect the legs and feet.
7. Protective sleeves
Made from leather to protect the arms.
8. Protective cover all
Made from light asbestos coated with
aluminum to protect the whole body during
welding.
5 BASIC JOINTS
BUTT JOINT is used to join two
members aligned in the same
plane.
CORNER AND TEE JOINTS are
used to join two members located
at right angles to each other.
Corner joint forms an L-shape, and
the tee joint has the shape of the
letter T.
A LAP JOINT, as the name
implies, is made by lapping one
piece of metal over another. This is
one of the strongest types of joints
available.
AN EDGE JOINT is used to join
the edges of two or more members
lying in the same plane.
TYPES OF WELDS
FILLET WELD – A weld joining two
surfaces approximately at right angles
to each other.
GROOVE WELD – A weld made in
the groove between two members to
be joined.
PLUG WELD – A weld made through
one piece of metal to join it to another
metal surfaces.
SPOT WELDING is "the welding
of overlapping pieces of metal at
small points by application of
pressure and electric current."
SURFACING is a welding process
used to apply a hard, wearresistant layer of metal to surfaces
or edges of worn-out parts.
WELDING POSITIONS
PLATE weld designations:
1F – flat position, fillet weld
2F – horizontal position, fillet weld
3F – vertical position, fillet weld
4F – overhead position, fillet weld
1G – flat position, groove weld
2G – horizontal position, groove weld
3G – vertical position, groove weld
4G – overhead position, groove weld
PIPE weld designations:
1F/1G – horizontal position pipe rotated
2F/2G– vertical position
5F/5g – horizontal position
6F/6G –pipe inclined position
AWS CODE FOR MILD STEEL ELECTRODE
1. Code consist of letter E plus 4 digits: Exxx
2. E stands for electric arc welding electrodes.
3. First 2 digits indicate minimum tensile strength of the weld
in thousands of PSI.
Examples:
E6011 - minimum tensile strength of deposited
- 60,000 PSI
E7018 - minimum tensile strength of deposited
- 70,000 PSI
The resistance of a material to
forces trying to pull it apart.
4. Third digit refers to welding position:
Exx1x - all positions
Exx2x - flat position only
Exx3x - flat and horizontal
5. Fourth digit refers to the type of current, type of
penetration, kind of arc, kind of coating and presence of
iron powder.
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