Although some structural adhesives are fast catching up, no other joining method can achieve such high strength as welding. This is because the welder melts the two metal surfaces and interlinks the two substrates. Sometimes, the weld joint is so strong it becomes stronger than the metal itself.
How Welding Works. Welding joins metals by melting and fusing them together, typically with the addition of a welding filler metal. The joints produced are strong – usually as strong as the metals joined, or even stronger.
Welders typically must be strong enough to lift and handle heavy materials. Welding is a physical job, so being in good physical condition, and able to bend, stoop or reach while working is generally considered to be helpful.
Both acute and chronic health risks are associated with welding fume. Occupational lung disease, including lung cancer, is the most common health risk, but welding can also affect the eyes and skin.
There's a common misconception that welding is stronger than bolting, but that simply isn't true. Bolting is just as strong as welding—and can be stronger in some situations. The strength of a weld is largely determined by the expertise of the welder.
One reason that airplanes are manufactured with riveted joints instead of welded joints is because the aluminum materials used in their construction isn't tolerant of heat. Most commercial aircraft are designed with an aluminum body. Not only is aluminum is inexpensive and readily available; it's also lightweight.
Modern-day welding technology provides an enhanced capacity for the flexible fabrication of different constructional structures. However, despite of this, welded joints can also represent the weakest part of structures and are susceptible to failure.
Pneumosiderosis, or more commonly referred to as Welder's lung, is an occupational lung disease that occurs after chronic inhalation of iron dust particles, especially in welders.
Welding fumes are far worse for you than smoking. Any time you weld you should be wearing a respirator with appropriate filters to the situation or even an approved fresh air supplied mask with an approved supply of fresh air(NOT off your shop compressor, it contains oil).
Becoming a welder takes a lot of talent, skill, and determination. However, it is unlikely to get a job as a welder without mastering the necessary techniques. A welder's profession necessitates a thorough understanding of architectural plans and other core competencies.
Welding in the overhead position—with the workpiece directly above the welder—is widely thought to be the most difficult welding position. Pipe welding is also well known to be particularly challenging welding work.
Average Nuclear Industry Welder Salary: $67,000 per year
Welders in the nuclear industry might work on pipelines, underwater, or in the military. They must pass a demanding screening process, including FBI clearance, to become nuclear certified, making it one of the most difficult welding positions to obtain.
When it comes to welding, this other compound typically comes in the form of a metal such as iron oxide or aluminum oxide. These compounds can decrease the strength of a weld joint over time as they become wedged in between the base and filler metals.
TIG welding is often considered the strongest weld since it produces extreme heat, and the slow cooling rate results in high tensile strength and ductility. MIG is also an excellent candidate for the strongest type of weld because it can create a strong joint.
Prolonged exposure to welding fume may cause lung damage and various types of cancer, including lung, larynx and urinary tract. . Health effects from certain fumes may include metal fume fever, stomach ulcers, kidney damage and nervous system damage.
Cons of the Welding Profession
Welders may experience some dangers and discomfort on the job including burns, eye discomfort, exposure to hazardous materials and a lot of physical effort. You may find yourself in tight spaces, working in hot weather or welding in wet and cold environments.
Weld spatters are a welders biggest enemy and have a massive negative influence on the productivity as they may force major downtimes. But there are ways to reduce weld spatters and therefore significantly decrease cleanup time as well as increase productivity.
The most common acute effect of exposure to intense welding fume is called Metal Fume Fever with symptoms similar to the common flu: chills, low-level fever, fatigue, nausea, sore throat, body aches, and pains usually lasting 24 hours.
Hazards from gas welding and brazing differ from arc welding hazards primarily because they involve metals with lower melting points. One such metal is lead. Overexposure of male workers to lead compounds is known to decrease the sexual drive and reduce the ability to produce healthy sperm.
Researchers have discovered that welders develop symptoms of parkinsonism — a general term referring to disorders that cause movement problems that resemble those of Parkinson's disease — because of prolonged exposure to manganese, a chemical element from welding fumes.
Breathe Freely.
When welding in confined spaces, toxic fumes may accumulate, or shielding gasses may replace breathable air. Use an exhaust hood to remove fumes from the area and ensure enough clean breathing air is available.
Weld from the bottom up.
Like building a house, you cannot start the bricks at the top. Weld metal is a liquid. When it goes in it needs support, that is why we need to always start at the bottom.
Too much heat will likely cause cracking in the weld, oxide inclusion, softening of the heat-affected zone, and porosity—all of which degrade your material and affect the quality of your weld, both structurally and cosmetically.
While it is true that welded pipe, in theory, is weaker when it is welded. Many advances in the welding process and quality checks have closed the gap. However, technically speaking, seamless pipe is still stronger on paper and in extreme applications.