Top 10 most importantthings to teach novice welders
Welding is a very difficult task. A perfect welder must have good patience, practice and knowledge about welding. To transform a novice welder into a professional one, you must train him perfectly. To train a novice welder, you must teach him 10 important things to make him a perfect welder.
Bellow, I provide 10 most important things teach the novice which may help them to develop their skills and stay safe during operation.
One: Safety first
Welding is a very risky job. During operation, a large amount of heat and electricity produced which is very dangerous. The arc is very dangerous for both the eyes and skin. So that safety is the most important thing in welding job. A little unconscious can spoil your life during welding. So, welders must wear the proper personal protective equipment all time.
The safety items are given bellow:
- Flame resistant gloves.
- Safety glasses.
- Welding helmet.
- Welding jacket(Long sleeved).
- Flame resistant clothing.
- Steel-toed shoes.
Enough ventilation and local exhaust of the arc is also important. Teach them how to keep the gas and smoke bellow TLV (threshold limit value), PEL (permissible exposure limit), OELs (Occupational exposure Limits) in their breathing zone and the working area. Always teach them to keep their heads away from the smoke.
To stay safe from electric shock, advise them to stand on a dry rubber mat or a dry board during operation.
Two: How to install the consumables properly?
Conductivity is an important fact for better welding quality. For better conductivity, welders must install the consumables perfectly. So it is important to teach the novice how to install the consumable parts like diffuser, nozzles, tips etc. perfectly.
Three: Cleaning of the base material.
Before welding, the welder must clean the base material. If the material contains oil, grease, and another type of dirt, it may reduce the welding quality. So it is important to teach novice welders about the cleaning methods of different types of material
Four: Welding procedures
Welding procedure is a recipe which and important for the balanced welding operation. It is both important for novices and experts. Welding procedures contain the details of gas flow rate, shielding gas mixture, voltage, current ranges etc to get the desired welding result.
The procedures also provide information about the type and diameter of the applicable filler metal and the wire feed speed for GMAW or FCAW welding application.
Five: How to use the filler metal.
Filler metal is a critical element for welding. Welders who don’t know the proper use of filler metal, can’t be able to weld perfectly. So it is important to teach them about the appropriate use of filler metal and how to use them for better welding.
Six: Stay comfortable during operation.
For longer work time and keep safe from injuries, they must learn how to stay cool and comfort during operation. Teach them how to minimize strength moves and constant motions. Teach them to use lightweight gun or torch with a comfortable handle.
Seven: Teach about the material properties.
Every material has different properties. The heating and cooling time of metal depend on the materials properties. So it is important to teach them about the material properties.
Eight: Inspect the welds visually.
Visually inspecting is the easiest way to inspect an element after completing welding. Novice welders should learn how to visually inspect an element after welding for defects like porosity, undercutting, excessive or lack of penetration, cracks etc.
Nine: Troubleshooting skills
Identification and rectification of welding problems are helpful skills for welders to reduce downtime and increase welding quality and productivity.
So, it is important for novice welders to learn few common troubleshooting like adjusting the gas flow rates accurately, identify gas leaks, identify problems of consumable and the plasma torch etc. They should also learn the adjustments of amperage and voltage settings to solve problems like excessive penetration, lack of penetration, undercutting etc.
To get better welding performance, welding system requires a tight maintenance. Novice welders also need to go through the maintenance procedures to learn the maintenance of a welding system. Good maintenance knowledge may help them to be a perfect welder.
If any novice goes through those 10 facts and train attentively, he will be able to perform any kind of welding operation perfectly.