Welding Basics and Applications

Joining similar metals using heat, potentially with pressure or filler material.

A process of joining parts to make a complete object.

Joining by fastening parts using bolts, screws, or rivets.

Welding where metals are heated to a plastic state and fused under pressure.

Welding where metals are heated above their melting point, fused together using a filler material, and allowed to solidify.

Material added during welding to fill the gap between the parts.

A fusion welding process using an electric arc.

A fusion welding process using gas and heat.

A luminous electrical discharge between two electrodes through ionized gas.

Power supply, electrode, workpiece, and welding leads to complete the circuit.

Transformers, motor generators, and rectifiers are used to supply high currents at low voltage for welding.

A type of welding machine using AC current; often the least expensive option.

A machine that produces DC current using a motor and generator mounted on a single shaft.

Welding machines are rated by their approximate amperage capacity (e.g., 150, 200 amps).

A machine that changes AC to DC using a rectifier, allowing use of either AC or DC current.

Needed to carry electricity for arc welding. They connect the welding machine to the electrode holder and the ground clamp.

Metallic wire coated with flux used as the positive electrode in arc welding; transfer current and create a shield.

Protective coating on welding electrodes. It vaporizes to create a shielding gas and provides a better weld.

Insulated tool that holds the electrode during welding and helps to transmit electrical current from cable to electrode

Used to complete the electrical circuit during welding by connecting to the work piece.

Electrodes are categorized by material (e.g. mild steel, copper, carbon).

Electrodes are classified by their coating thickness (e.g., light coated, heavily coated).

Measured by the diameter of the core wire; provides the right amount of material for the job.

Used for cleaning and preparing surfaces before welding, removing rust, scale, and other impurities.

Used to remove slag, the hardened layer of flux material formed on welds.

The hardened layer of flux material formed on welds, containing impurities from the weld metal.

Small molten metal drops dispersed around weld heads during welding.

Process of removing spatter and slag from weld beads, ensuring a smooth and clean weld.

Protects the eyes and face from harmful arc rays, spatter, and flying hot metal particles.

Different ways to orient the workpiece and electrode during welding, affecting weld quality and accessibility.

Welding performed from the upper side of a horizontal joint, with the weld face approximately horizontal.

Welding on the upper side of a horizontal surface and against a vertical surface.

Welding with the axis of the weld approximately vertical.

Welding performed from the underside of a joint.

A type of joint where the edges of two pieces are beveled to form a V-shape, allowing for better penetration during welding.

Choosing the right electrode diameter based on the thickness of the workpiece to ensure proper penetration and weld quality.

Adjusting the welding current based on the electrode size to control the heat input and weld quality.