ix Contents Part 1 Welding Fundamentals . . . . . . . . . . . 2 Chapter 1 Safety in the Welding Shop. . . . . . . . . . . . . . . . . . . . .3 1.1 Accidents. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 1.2 General Shop Safety . . . . . . . . . . . . . . . . . . . . . 4 1.3 Safety in the Welding Environment . . . . . . . 11 1.4 Oxyfuel Gas Welding and Cutting Safety. . . . . . . . . . . . . . . . . . . . . . 16 1.5 Arc Welding and Cutting Safety . . . . . . . . . . 19 1.6 Resistance Welding Safety . . . . . . . . . . . . . . . 21 1.7 Safety around Welding Robots . . . . . . . . . . . 22 1.8 Special Welding Process Safety . . . . . . . . . . . 22 Chapter 2 Print Reading . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25 2.1 Types of Drawings. . . . . . . . . . . . . . . . . . . . . . 25 2.2 Orthographic Projection . . . . . . . . . . . . . . . . . 26 2.3 Using a Working Drawing . . . . . . . . . . . . . . . 29 2.4 Types of Lines Used on a Drawing . . . . . . . . 32 2.5 Drawings Made to a Scale . . . . . . . . . . . . . . . 33 2.6 The Title Block . . . . . . . . . . . . . . . . . . . . . . . . . 33 Chapter 3 Welding Joints, Positions, and Symbols . . . . . . . 37 3.1 Basic Weld Joints . . . . . . . . . . . . . . . . . . . . . . . 37 3.2 Types of Welds . . . . . . . . . . . . . . . . . . . . . . . . . 42 3.3 Joint Geometry . . . . . . . . . . . . . . . . . . . . . . . . . 44 3.4 Welding Positions . . . . . . . . . . . . . . . . . . . . . . 45 3.5 The Welding Symbol. . . . . . . . . . . . . . . . . . . . 48 3.6 Review of Welding Symbols . . . . . . . . . . . . . 62 3.7 Electrode Angles . . . . . . . . . . . . . . . . . . . . . . . 62 Chapter 4 Welding and Cutting Processes. . . . . . . . . . . . . . . 69 4.1 Arc Welding Processes . . . . . . . . . . . . . . . . . . 71 4.2 Oxyfuel Joining Processes . . . . . . . . . . . . . . . 76 4.3 Oxygen Cutting Processes . . . . . . . . . . . . . . . 79 4.4 Resistance Welding Processes . . . . . . . . . . . . 82 4.5 Arc Cutting Processes . . . . . . . . . . . . . . . . . . . 86 4.6 Specialized Arc Welding Processes . . . . . . . 89 4.7 Solid-State Welding Processes . . . . . . . . . . . . 91 4.8 Other Welding Processes . . . . . . . . . . . . . . . . 97 Part 2 Shielded Metal Arc Welding . . . . .102 Chapter 5 Shielded Metal Arc Welding Equipment and Supplies. . . . . . . . . . . . . . . . . . . . 103 5.1 Shielded Metal Arc Welding Station. . . . . . 103 5.2 Arc Welding Power Source Classifi cations. . . . . . . . . . . . . . . . . . . . . . . . . 104 5.3 Constant Current Power Sources. . . . . . . . . 104 5.4 Arc Welding Power Source Specifi cations . . . . . . . . . . . . . . . . . . . . . . . . . 108 5.5 Welding Leads . . . . . . . . . . . . . . . . . . . . . . . . 109 5.6 SMAW Electrodes . . . . . . . . . . . . . . . . . . . . . 112 5.7 Carbon and Low-Alloy Steel Covered Electrode Classifi cation. . . . . . . . . 114 5.8 Nonferrous Electrode Classifi cations . . . . . 119 5.9 Electrode Care . . . . . . . . . . . . . . . . . . . . . . . . 120 5.10 Power Source Remote Controls . . . . . . . . . . 121 5.11 Weld-Cleaning Equipment. . . . . . . . . . . . . . 121 5.12 Shields and Helmets . . . . . . . . . . . . . . . . . . . 122 5.13 Special Arc Welder Clothing . . . . . . . . . . . . 124 Chapter 6 Shielded Metal Arc Welding . . . . . . . . . . . . . . . . . 127 6.1 Direct Current (DC) Arc Welding Fundamentals . . . . . . . . . . . . . 127 6.2 Alternating Current (AC) Arc Welding Fundamentals . . . . . . . . . . . . . 131 6.3 Selecting an Arc Welding Machine. . . . . . . 132 6.4 Inspecting an Arc Welding Station . . . . . . . 134 6.5 Safety, Protective Clothing, and Shielding . . . . . . . . . . . . . . . . . . . . . . . . . 135 6.6 Starting, Stopping, and Adjusting the Arc Welding Power Source for SMAW. . . . 136 6.7 DC Arc Blow. . . . . . . . . . . . . . . . . . . . . . . . . . 145 6.8 Arc Welded Joint Designs. . . . . . . . . . . . . . . 147 6.9 SMAW Welding Techniques . . . . . . . . . . . . 150 6.10 SMAW Safety Review . . . . . . . . . . . . . . . . . . 165