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PowerPoint to accompany
Welding
Principles and Practices
Third Edition
Sacks and Bohnart
1
History of
Welding
Chapter 1
1 - 2
Overview
Welding is joining two pieces of metal by:
Heating to temperature high enough to cause
softening or melting
With or without application of pressure
With or without use of filler metal
Melting point same as metals beginning joined or melting
point below metals but about 800 F
New methods, applications and systems
Tremendous progress in short time
Usually best method to use when fastening metal
1 - 3
History of Metalworking
Began when people found they could shape
rocks by chipping them with other rocks
Copper probably first metal to be worked
Ductile (easily hammered, bent or drawn)
In Egypt as early as 4000 B.C. and USA before
2000 B.C.
Welding began more than 3000 years ago
Hot or cold metals hammered to obtain forge weld
Forged metals, bronze and iron mentioned in Old
Testament
1 - 4
History of Metalworking
Bronze developed between 3000 and 2000 B.C.
Iron became known to Europe about 1000 B.C.
Several thousand years after use of copper
Philistines had four iron furnaces about 1300 B.C.
Produced swords, chisels, daggers, and spearheads
Egyptians began making iron tools during period of
900 to 850 B.C.
Replaced bronze as metal used in manufacture of
utensils, armor and other applications after 800 B.C.
1 - 5
History of Metalworking
Famous Damascus swords and daggers made in
Syria about 1300 B.C.
Sought because of their strength and toughness
Made by forge-welding iron bars of different
degrees of hardness, drawing them down, and
repeating process many times
Working of metals followed one another in
great ancient civilizations
Copper, bronze, silver, gold, and iron
1 - 6
History of Metalworking
Time of Roman Empire
Iron use common in Europe, Near East and Far East
Chinese developed ability to make steel from
wrought iron in 589 A.D.
Belgians responsible for progress with steel in
Europe
Japan manufactured steel by repeated welding
and forging and controlling amount of carbon
by use of fluxes
Produced famous Samurai sword
1 - 7
History of Metalworking
Blast furnace developed for melting iron about
1000 to 1200 A. D.
Fourteenth and fifteenth centuries saw great
improvements in design of blast furnaces
First cast iron cannon produced in early 1600s
Industrial Revolution in the middle of the
eighteenth century brought many
improvements
1 - 8
History of Metalworking
Present factory system of mass production
introduced
American, Eli Whitney, developed idea of
interchanging parts in manufacture of arms
Working of dies and molds became
commonplace by beginning of nineteenth
century
Henry Ford involved in developing assembly
line method for manufacturing automobiles
early in twentieth century
1 - 9
Early Developments in Welding
Edmund Davy discovered acetylene at beginning
of nineteenth century
Sir Humphrey Davy discovered the electric arc
in 1801
Concerned with use of arc for illumination
Demonstrated possible to maintain high voltage arc
for varying periods of time by 1809
Workable electrical generating devices invented
and developed on practical basis by 1850
These inventions were forerunner of
present arc welding process.
1 - 10
History of Fusion Welding
First documented instance done by Auguste de
Meritens in 1881
Welded lead battery plates together with carbon
electrode
Two of Auguste's pupils, N. Benardos and S.
Olszewski continued work and issued patent
for welding process using carbon electrodes
and electric power source four years later
Primary goal was repair welding
1 - 11
Bare Metal Electrode Welding
Introduced in 1888 by N. G. Slavianoff (Russian)
Discovery first recognized in western Europe in 1892
C. L. Coffin was pioneer of welding industry in
United States
1889 received patent on equipment and process for
flash-butt welding
1890 received additional patents for spot welding
1892 received patent for bare metal electrode arc
welding process
Without knowledge of Slavianoff's work
1 - 12
History of Metalworking
Foresche and Picard developed first
commercial oxyacetylene welding torch at turn
of the century
Electric arc welding method used in US until
about 1920
Handicapped because of welds produced by these
electrodes not as strong as metal being welded
Welding arc very unstable
1 - 13
History of Metalworking
In 1907 Kjellberg (Swedish engineer) received
patent covering electrode-coating process
Coating thin and acted only as stabilizer of arc
Produced welds little better than bare electrodes
In 1912 Kjellberg received another patent for
electrode with heavier coating made of
asbestos with binder of sodium silicate
In 1908, Benardos patented electroslag process
of welding thick plates in one pass
1 - 14
History of Metalworking
Technology of welding progressed slowly until
World War I
Demands of war called for improved methods of
fabrication
End of war, welding widely accepted
Research on coated electrodes through 1920s
resulted in electrode coatings and improved
core wire
1 - 15
Multipass Welds
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Ability to make multipass welds
such as this one, on plate and pipe,
led to growth of industry. Welds are
sound and have uniform appearance.
Pass 1
Pass 2
Pass 3
1 - 16
History of Metalworking
Stick welding process
Advanced rapidly due to electrode coatings and
improved core wire
Now called shielded metal arc welding (SMAW)
X-ray development
Possible to examine internal soundness of welded
joints
1 - 17
Shipbuilding
5,171 vessels constructed to American Bureau
of Shipping standard
Through 1945
During Maritime Commission wartime
shipbuilding program
Welding was replacing riveting as main
method of assembly
1 - 18
Development of Modern Welding
Design of welding machines changed very little
during postwar period
Done with d.c. current from batteries
Use of a.c. welding machines occurred in late
1920 and increased in the early 1930s
First high frequency a.c. industrial machine
introduced in 1936 by Miller Electric Manufacturing
Company
High rate of metal deposition and absence of arc blow

1 - 19
Inert Gas Welding
World War II spurred development
Possible to produce welds of high purity and
critical application
Patent issued in 1930 to Hobart and Devers for
use of electric arc within inert gas atmosphere
Not well received because high cost of argon and
helium and lack of suitable torch equipment
1 - 20
GTAW Welding
Tungsten electrode replace magnesium
procedure
Patent issue in 1942
Linde Company developed gas tungsten arc
welding (GTAW)
Also called tungsten inert gas (TIG) process or
HELIARC
Perfected water-cooled torch capable of high
amperage
1 - 21
Tungsten Inert Gas (TIG) Process
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An aluminum weld made using
the TIG process. The welding
of aluminum is no longer a
problem and can be done with
the same ease as that of steel.
1 - 22
GTAW Welding
First done with rotating d.c. welding machines
Later a.c. units developed
In 1950s
Selenium rectifier type d.c. welding machines
a.c.-d.c. rectifier welding machines with built-in
frequency for GTAW welding became available
Miller Electric Manufacturing Company
developed Miller controlled-wave a.c. welder
for critical welds on aircraft and missiles
1 - 23
Development of Modern
Welding (continued)
Use of aluminum and magnesium increased
Development of GTAW welding
Desirable characteristics of reduced weight and
resistance to corrosion
Thicker materials in construction, which
required preheating using GTAW welding
U.S. patent issued in 1948 for gas metal arc
welding (GMAW) process
Superseded earlier terms of metal inert gas (MIG)
and metal active gas (MAG)
1 - 24
GMAW Process
Concentrates high heat at a focal point
Produces
Small heat-affected zone
Narrow bead width
Deep penetration
Faster welding
speed
Now used in all
industries
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Responsible for over
70 percent of welds
being performed today.
St Louis Car. Co.
1 - 25
Development of Modern
Welding (continued)
Rapid changes occurred in 1980s and 1990s
Exotic multiple gas mixes
State-of-art electrodes
Onboard computers
Robotic welding
Methods developing that may change way
welds made in future
1 - 26
Processes Involving
Use of the Electric Arc
Arc spot welding
Atomic-hydrogen welding
Electrogas
Plasma arc welding
Stud welding
Submerged arc welding
Underwater arc welding
1 - 27
Specialized Processes Involving
Use of the Electric Arc
Cold welding
Electron beam welding
Explosive welding
Force welding
Friction welding
Friction stir welding
Laser welding
Oxyhydrogen welding
Thermit welding
Ultrasonic welding
Welding of plastics
1 - 28
Industry Demand
Over 90 welding processes
Force new and improved developments in
machines, gases, torches, electrodes,
procedures, and technology
Constant research for new metals done by
shipbuilding, space and nuclear industries
Spurs research in welding
1 - 29
Welding Associations
American National Standards Institute (ANSI)
American Petroleum Institute (API)
American Society of Mechanical Engineers
(ASME)
American Welding Society (AWS)
American Bureau of Shipping (ABS)
Provide guidance and standards relating
to the welding industry.
1 - 30
Welding as an Occupation
Can be certified by AWS, ASME and API
Tests difficult and require many hours of practice
Key positions in major industries
Important to economic welfare of country
Gender friendly
Done in every civilized country in the world
Offer prestige and security
Chances for advancement excellent
1 - 31
Industrial Welding Applications
More than 90 different welding processes
Divided into three major types
Arc
Gas
Resistance
Number of other types used to lesser extent
Induction, forge, thermit, flow, and brazing
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Resistance Welding
Includes spot welding, seam welding, flash
welding, projection welding, and other similar
processes performed on machines
Operators usually taught on job
Semiskilled workers do not need specific hands-on-
welding skills
1 - 33
Arc and Gas Welding
Focus of this text
Combine art and science
Welders have almost complete control of the
process
Must know properties of metals to weld; which
weld process to use; and how to plan, measure, and
fabricate
1 - 34
Welding Positions
As well as flat
and horizontal
Vertical
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Miller Electric Mfg. Co.
Overhead
General Electric Corp.
1 - 35
Qualifications and Personal
Characteristics
Welders certified for ability to do work and
work is inspected
Required to pass periodic qualification tests
Certifications issued according to kind and
gauge of metal and specific welding process
Can hold several different certifications
simultaneously
1 - 36
Example of Magnetic-Particle
Testing in Building
Weld testing and
inspection give
proof of the
soundness of welds.
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Circlesafe Aerosol/Circle Systems, Inc.
1 - 37
Basic Tasks
Gas weld
Attaching proper tip and adjusting welding
regulators for proper volume and gas pressures
Electric arc welding
Regulate welding machine for proper welding
current, select proper electrode size and type, and
right shielding gas
Need steady hand and have good visualization
skills

1 - 38
Master Welder Job Examples
Welds in these tanks must
meet X-ray requirements
and pass a dye penetrant
test. Tanks are often lined
with a very thin layer of
pure silver.
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Nooter Corp
Creating Art!
Enrique Vega
1 - 39
Master Welder
Master craftsperson
Able to weld all steels and alloys
Plus nickel, aluminum, tantalum, titanium,
zirconium, and their alloys and claddings
Welds of highest quality
Welds meet requirement of job
Delicate welding of silver and gold
Heavy pressure vessels requiring 4-inch plate
1 - 40
Welding Occupations Requiring
a High School Education
Welding operator
Welding fitter
Combination welder
Master welder
Welding supervisor
Welding analyst
Inspector
Welding foreman
Welding superintendent
Equipment sales
Sales demonstrator
Sales troubleshooter
Welding instructor
Robotics welder operator
Jog or fabrication shop
owner
1 - 41
Welding Occupations Requiring
a College Education
Welding engineer
(metallurgical)
Welding development
engineer
Welding research
engineer
Welding engineer

Technical editor
Welding professor
Certified welding inspector
(AWS/CWI)
Corporation executive
Owner of welding business
Sales engineer
1 - 42
Safety and Working Conditions
Indoors or outdoors
Noisy
Hearing protection needed
Awkward positions
Spacious surroundings or
cramped quarters
High off ground in
scaffolds with safety
harness
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The Lincoln Electric Corp.
1 - 43
Job Hazards
Fire danger
Burns (including "sunburn" from electric arcs)
Noxious fumes from materials vaporized at
high temperatures
Eyestrain
Welders flash
Electric shock
Hazards can be minimized
or eliminated by use
of proper protective
clothing and equipment.
1 - 44
Ways to Stay Current
1. Read trade journals, service manuals,
textbooks, and trade catalogs
2. Join associations such as the American
Welding Society
3. Research topics on the Internet
4. Trade trips with your peers