Welder
Encyclopedia
A welder is a tradesman who specializes in welding
materials together. The materials to be joined can be metal
s (such as steel
, aluminum, brass
, stainless steel
etc.) or varieties of plastic
or polymer
. Welders typically have to have good dexterity and attention to detail, as well as some technical knowledge about the materials being joined and best practices in the field.
in the form of heavy leather
glove
s and protective long sleeve jackets to avoid exposure to extreme heat and flames. Additionally, the brightness of the weld area leads to a condition called arc eye in which ultraviolet light causes the inflammation of the cornea
and can burn the retina
s of the eyes. Full face welding helmet
s with dark face plates are worn to prevent this exposure, and in recent years, new helmet models have been produced that feature a face plate that self-darkens upon exposure to high amounts of UV light. To protect bystanders, opaque welding curtains often surround the welding area. These curtains, made of a polyvinyl chloride
plastic film, shield nearby workers from exposure to the UV light from the electric arc, but should not be used to replace the filter
glass used in helmets.
Welders are also often exposed to dangerous gases and particulate matter. Processes like flux-cored arc welding and shielded metal arc welding produce smoke
containing particles of various types of oxide
s, which in some cases can lead to medical conditions like metal fume fever
. The size of the particles in question tends to influence the toxicity
of the fumes, with smaller particles presenting a greater danger. Additionally, many processes produce fumes and various gases, most commonly carbon dioxide
and ozone
, that can prove dangerous if ventilation is inadequate. Furthermore, because the use of compressed gases and flames in many welding processes pose an explosion and fire risk, some common precautions include limiting the amount of oxygen
in the air and keeping combustible materials away from the workplace. Welders with expertise in welding pressurized vessels, including submarine hulls, industrial boilers, and power plant heat exchangers and boilers, are generally referred to as boilermakers.
Welding
Welding is a fabrication or sculptural process that joins materials, usually metals or thermoplastics, by causing coalescence. This is often done by melting the workpieces and adding a filler material to form a pool of molten material that cools to become a strong joint, with pressure sometimes...
materials together. The materials to be joined can be metal
Metal
A metal , is an element, compound, or alloy that is a good conductor of both electricity and heat. Metals are usually malleable and shiny, that is they reflect most of incident light...
s (such as steel
Steel
Steel is an alloy that consists mostly of iron and has a carbon content between 0.2% and 2.1% by weight, depending on the grade. Carbon is the most common alloying material for iron, but various other alloying elements are used, such as manganese, chromium, vanadium, and tungsten...
, aluminum, brass
Brass
Brass is an alloy of copper and zinc; the proportions of zinc and copper can be varied to create a range of brasses with varying properties.In comparison, bronze is principally an alloy of copper and tin...
, stainless steel
Stainless steel
In metallurgy, stainless steel, also known as inox steel or inox from French "inoxydable", is defined as a steel alloy with a minimum of 10.5 or 11% chromium content by mass....
etc.) or varieties of plastic
Plastic
A plastic material is any of a wide range of synthetic or semi-synthetic organic solids used in the manufacture of industrial products. Plastics are typically polymers of high molecular mass, and may contain other substances to improve performance and/or reduce production costs...
or polymer
Polymer
A polymer is a large molecule composed of repeating structural units. These subunits are typically connected by covalent chemical bonds...
. Welders typically have to have good dexterity and attention to detail, as well as some technical knowledge about the materials being joined and best practices in the field.
Safety issues
Welding, without the proper precautions appropriate for the process, can be a dangerous and unhealthy practice. However, with the use of new technology and proper protection, the risks of injury and death associated with welding can be greatly reduced. Because many common welding procedures involve an open electric arc or flame, the risk of burns is significant. To prevent them, welders wear personal protective equipmentPersonal protective equipment
Personal protective equipment refers to protective clothing, helmets, goggles, or other garment or equipment designed to protect the wearer's body from injury by blunt impacts, electrical hazards, heat, chemicals, and infection, for job-related occupational safety and health purposes, and in...
in the form of heavy leather
Leather
Leather is a durable and flexible material created via the tanning of putrescible animal rawhide and skin, primarily cattlehide. It can be produced through different manufacturing processes, ranging from cottage industry to heavy industry.-Forms:...
glove
Glove
A glove is a garment covering the hand. Gloves have separate sheaths or openings for each finger and the thumb; if there is an opening but no covering sheath for each finger they are called "fingerless gloves". Fingerless gloves with one large opening rather than individual openings for each...
s and protective long sleeve jackets to avoid exposure to extreme heat and flames. Additionally, the brightness of the weld area leads to a condition called arc eye in which ultraviolet light causes the inflammation of the cornea
Cornea
The cornea is the transparent front part of the eye that covers the iris, pupil, and anterior chamber. Together with the lens, the cornea refracts light, with the cornea accounting for approximately two-thirds of the eye's total optical power. In humans, the refractive power of the cornea is...
and can burn the retina
Retina
The vertebrate retina is a light-sensitive tissue lining the inner surface of the eye. The optics of the eye create an image of the visual world on the retina, which serves much the same function as the film in a camera. Light striking the retina initiates a cascade of chemical and electrical...
s of the eyes. Full face welding helmet
Welding helmet
Welding helmets are headgear used when performing certain types of welding to protect the eyes, face and neck from flash burn, ultraviolet light, sparks, infrared light, and heat. Most commonly used with arc welding processes such as shielded metal arc welding, gas tungsten arc welding, and gas...
s with dark face plates are worn to prevent this exposure, and in recent years, new helmet models have been produced that feature a face plate that self-darkens upon exposure to high amounts of UV light. To protect bystanders, opaque welding curtains often surround the welding area. These curtains, made of a polyvinyl chloride
Polyvinyl chloride
Polyvinyl chloride, commonly abbreviated PVC, is a thermoplastic polymer. It is a vinyl polymer constructed of repeating vinyl groups having one hydrogen replaced by chloride. Polyvinyl chloride is the third most widely produced plastic, after polyethylene and polypropylene. PVC is widely used in...
plastic film, shield nearby workers from exposure to the UV light from the electric arc, but should not be used to replace the filter
Filter (optics)
Optical filters are devices which selectively transmit light of different wavelengths, usually implemented as plane glass or plastic devices in the optical path which are either dyed in the mass or have interference coatings....
glass used in helmets.
Welders are also often exposed to dangerous gases and particulate matter. Processes like flux-cored arc welding and shielded metal arc welding produce smoke
Smoke
Smoke is a collection of airborne solid and liquid particulates and gases emitted when a material undergoes combustion or pyrolysis, together with the quantity of air that is entrained or otherwise mixed into the mass. It is commonly an unwanted by-product of fires , but may also be used for pest...
containing particles of various types of oxide
Oxide
An oxide is a chemical compound that contains at least one oxygen atom in its chemical formula. Metal oxides typically contain an anion of oxygen in the oxidation state of −2....
s, which in some cases can lead to medical conditions like metal fume fever
Metal fume fever
Metal fume fever also known as brass founders' ague, brass shakes, zinc shakes, Galvie Flu, or Monday morning fever is an illness caused primarily by exposure to certain fumes...
. The size of the particles in question tends to influence the toxicity
Toxicity
Toxicity is the degree to which a substance can damage a living or non-living organisms. Toxicity can refer to the effect on a whole organism, such as an animal, bacterium, or plant, as well as the effect on a substructure of the organism, such as a cell or an organ , such as the liver...
of the fumes, with smaller particles presenting a greater danger. Additionally, many processes produce fumes and various gases, most commonly carbon dioxide
Carbon dioxide
Carbon dioxide is a naturally occurring chemical compound composed of two oxygen atoms covalently bonded to a single carbon atom...
and ozone
Ozone
Ozone , or trioxygen, is a triatomic molecule, consisting of three oxygen atoms. It is an allotrope of oxygen that is much less stable than the diatomic allotrope...
, that can prove dangerous if ventilation is inadequate. Furthermore, because the use of compressed gases and flames in many welding processes pose an explosion and fire risk, some common precautions include limiting the amount of oxygen
Oxygen
Oxygen is the element with atomic number 8 and represented by the symbol O. Its name derives from the Greek roots ὀξύς and -γενής , because at the time of naming, it was mistakenly thought that all acids required oxygen in their composition...
in the air and keeping combustible materials away from the workplace. Welders with expertise in welding pressurized vessels, including submarine hulls, industrial boilers, and power plant heat exchangers and boilers, are generally referred to as boilermakers.
Further reading
- ASM International (2003). Trends in Welding Research. Materials Park, OhioOhioOhio is a Midwestern state in the United States. The 34th largest state by area in the U.S.,it is the 7th‑most populous with over 11.5 million residents, containing several major American cities and seven metropolitan areas with populations of 500,000 or more.The state's capital is Columbus...
: ASM International. ISBN 0-87170-780-2 - Hicks, John (1999). Welded Joint Design. New YorkNew York CityNew York is the most populous city in the United States and the center of the New York Metropolitan Area, one of the most populous metropolitan areas in the world. New York exerts a significant impact upon global commerce, finance, media, art, fashion, research, technology, education, and...
: Industrial Press. ISBN 0-8311-3130-6. - Kalpakjian, Serope and Steven R. Schmid (2001). Manufacturing Engineering and Technology. Prentice Hall. ISBN 0-201-36131-0.