Thursday, July 9, 2015

Top 13 Things to Teach Your Novice Welders (Part 1)

Learning to weld is not easy. Just like a solider, one needs steadfast spirit, patience to learn. It also takes practice and firm foundation of knowledge. Following are 13 important things that companies can consider to teach their novice welders. Ensure they grasp those things for skilling up, gaining confidence needed to increase proficiency, and staying safe in the process.

See also:
Top 13 Things to Teach Your Novice Welders (Part 2)

 1. Put safety first

Teach welders to wear proper personal protective equipment
Importantly, welders keep themselves safe from electricity and heat generated from the welding process. As beautiful-like-firework as it is, the arc does harm to both eyes and skin. That’s why welders need wear appropriate personal protective equipment at all times. Those items include safety glasses, a welding helmet, flame-resistant gloves, a long sleeved welding jacket. Steel toed shoes and flame resistant clothing are also recommended. 

Aside from PPE, welders importantly employ enough local exhaust, ventilation at the arc, or use both to maintain the gases and fumes below Threshold Limit Value (TLV)/ Permissible Exposure Limit (PEL)/ Occupational Exposure Limits (OELs) in the general area and their breathing zone. 

Train novice welders to keep their heads out of fumes. 

Plus, explain to novice welders about how important it is for reading and comprehending the manufacturer’s equipment instructions, the workplace’s safety practices, safety instructions on the label, material safety data sheet for filler metals being employed. Overall, remind new welding workers of all needed precautions for their own and others protection.

From time to time, check for standing on a dry rubber mat (indoors) or a dry board (outdoors), and ground connections. That way also can mitigate the possibility of electric shock, further protecting welders.

 2. Properly install consumables

One important factor in attaining good weld quality is good conductivity (also, the ability for the electric current to run along the welding circuit). At all times, new welders should install their consumables like nozzles, diffusers, contact tips, etc. aligned with the manufacturer’s recommendation, ensuring each component is tightened securely. For instance, in the gas metal arc welding (GMAW) operation, with the secure connection between the GMAW gun neck and diffuser, shielding gas leaks would be prevented. Not all, such secure connections will give out the surface area necessary to carry the electric current through the GMAW gun and create a stable arc. They also help limit weld defects, help with consistent productivity and lower the risk of overheating related premature consumable failure.

3. Cleanliness is significant

Teach welders about proper cleaning procedure for particular base material being welded
It is definitely important to clean the base material before welding, and as necessary between weld passes. Oil, grease, dirt and other debris can enter the weld pool, inducing contamination. That will lead to bad weld quality and expensive rework. New welders need be taught as to the appropriate cleaning procedure for the specific base material being welded. 

In some cases, it is sufficient to wipe the base material using a dry, clean cloth. Still, more precautions need be taken when welding on aluminium, for instance. The welder will need use the stainless steel wire brush specified for aluminium to wipe out the joint prior to welding. That way will get rid of dirt and any oxide still residing on the aluminium's surface.

No matter what material, it is critical to properly instruct welders about cleaning before welding starts.

4. Always abide by welding procedures

Follow weld procedures
Like a recipe that makes a meal, welding procedures are needed to make consistent welds. Not just new welders but the experienced need grasp the importance of those procedures and always follow them.

The procedures for a certain application have been meticulously decided and qualified by the experts to guarantee that the recommended parameters can give out the desired results. 

Weld procedures cover such details as suggested gas flow rate, shielding gas mixture, voltage and current ranges. Those procedures also give information on type and diamter of filler metal to apply, and the appropriate wire feed speed in case of GMAW or flux cored arc welding (FCAW) application. 

5. Seize the importance of filler metal

Filler metals are consider a specially important but sometimes confusing component of welding system. It will be good for new welders if they familiarize themselves with attributes of different types of wires, inclusive of flux cored and metal cored wires, along with respective welding techniques. For example, those welding workers should learn whether their specific filler metal asks for a ‘push’ or ‘pull’ technique. Going by such old adages as “If there is slag, you drag” may help; it shows that flux cored wires that produce slag should be handled using the ‘pull’ technique. Also, new welders should form the habit of consulting the manufacturer’s spec sheet for more operating recommendations.

Also, learning to properly handle and store filler metals is important for new welders. They should put on clean gloves whenever handling the filler metals, and if they are in charge of storing them, they should do so in the clean and dry environment.

6. Keep comfortable

Staying cool and comfortable during welding process can help welders with lessened injuries and repetitive movement and reduced overall fatigue. If possible, they should learn to minimize their total strength moves or constant motion. Plus, the welders should employ a GTAW torch or GMAW gun with a comfy handle and cable style because those factors both make up the equipment’s manoeuvrability and weight.

Plus, new welders should be motivated to involve in raising efficiency of their welding workspace. Commonly, the more engaged a welder is in offering input about the work, the more satisfied he/ she will be. Also, such engagement can help guarantee better safety compliance and reduced welders’ compensation cost for injuries.


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