College of Engineering Shop Procedure

WELDING SAFETY PROCEDURE

Dept: Multi-department Laboratory: Student Machine Shop Rm: HML 112

Authored by: ________________________________________ ____________

Dick Sevier, Research Support Engr. Date:
Filename: Welding SOP 29-Feb-12.docx Revision: 1

Procedure Type Process/Protocol Chemical Hazard Class

This procedure provides general instructions on how to use the TIG, MIG and arch
welders in the student shop.
Brief Overview & This procedure is primarily intended to provide rules for the safe use of welders.
Scope Successful welding usually requires much practice, in-depth knowledge and mentoring;
none of which can be provide by this SOP. Also, maintenance operations of the tool
are beyond the scope of this document due to the skill required and diversity of tools
and processes associated with these operations.
Damage to eyes from bright light from welding.
Inhalation of toxic fumes from welding process.
Potential Hazards
Combustion of nearby materials due to spatter of welding
Burns due to molten spatter from welding.
Engr. Controls Exhaust snorkel, welding curtains
PPE Welding hood, safety glasses, gloves, aprons
Add'l Equipment,
Clamps,
Tools:
Matls, Supplies: Welding wire (TIG, MIG), electrodes (arc), compressed gases
Addl Training All mandatory shop training modules
Requirements Compressed gas cylinder SOP
Special Requirements:
Handling &
n/a
Facilities
Spill & Incident n/a
Decontamination/
All shop consumables to be disposed of per Shop Waste Materials Disposal SOP.
Waste Disposal
Sources/ Some content for this procedure have been taken from the other sources. See citing in
References specific areas.

TABLE OF CONTENTS

GENERAL WELDING SAFETY RULES ......................................................................................... 3

1. Fire Protection ......................................................................................................................... 3
2. Ventilation and Toxic Gases ................................................................................................... 3
3. Eye Protection (1) .................................................................................................................... 3
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4. Preventing Burns..................................................................................................................... 3
5. Compressed Gas Cylinders .................................................................................................... 4
6. Electrical Welding (Arc and Wire Feed) ................................................................................. 4
ADDITIONAL WELDING CONSIDERATIONS ............................................................................... 5
7. College of Engineering Student Shop Welding Processes .................................................. 5
8. Hands-On Welding Training.................................................................................................... 6
9. Structural Welding................................................................................................................... 6

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GENERAL WELDING SAFETY RULES
1. Fire Protection
a. Make sure you know the location of the nearest fire extinguisher and that is it within 35 feet of the
welding operation.
b. Make sure fire extinguisher is properly charged (green zone).
c. Keep combustibles at least 15 feet from welding area.
d. Do not weld in any area where dust or flammable vapors are present.
e. After completion of work, inspect area to ensure it is free of sparks, glowing embers, and flames.
f. Turn off gas supplies when not welding.
g. Do not store compressed gases, hoses and torches in a confined area.
h. If welding is to be done outside of the welding area, the shop supervisor must first provide approval.
2. Ventilation and Toxic Gases
a. Welding produces toxic fumes and gases, which can be hazardous to your health.
b. When possible, restrict welding to the welding area in HML 112 and use the exhaust snorkel to
remove the fumes from your welding process.
c. Keep your head out of the fumes so that you do not breathe them.
d. Read and understand the Material Safety Data Sheets (MSDSs) for the materials you are welding and
are welding with.
e. Do not weld any metals that contain or are coated with cadmium, zinc (galvanized), lead, fluorine
compounds, or other toxic materials, as these can emit toxic gases. Similarly, do not weld dirty metals
or used drums or like items that may have previously held a potentially hazardous material.
3. Eye Protection (1)
a. Rays from the welding process produce intense visible and invisible (ultraviolet and infrared) rays that
can burn eyes and skin. Sparks fly off from the weld.
b. Wear an approved welding helmet fitted with a proper shade of filter lenses to protect your face and
eyes from arc rays and sparks when welding or watching (see ANSI Z49.1 and Z87.1 listed in Safety
Standards).
c. Welding, chipping, wire brushing, and grinding cause sparks and flying metal. As welds cool, they can
throw off slag. Wear approved safety glasses with side shields under your helmet.
d. Use protective screens or barriers to protect others from flash, glare and sparks; warn others not to
watch the arc.
(1) Content from Miller Electric Mfg, http://www.millerwelds.com/pdf/safety/som_eng_200704.pdf
4. Preventing Burns
WARNING: Hot parts can burn!
a. Allow parts to cool before handling.
b. Handle using proper tools and/or heavy, insulated welding gloves and clothing to prevent burns.
c. Do not touch hot parts without gloves.
d. Wear oil-free protective garments such as leather gloves, heavy shirt, cuffless trousers, high shoes,
and a cap.

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e. Remove any combustibles from your person, such as a lighter or matches, before doing any welding.

5. Compressed Gas Cylinders

a. Ensure cylinders have sufficient gas and fittings are tight.
b. Inspect all equipment, particularly hoses, are free of defects.
c. Use a cart when moving compressed gas cylinders.
d. Contact a supervisor if you find a problem with the welder.
6. Electrical Welding (Arc and Wire Feed)
a. Ensure electrical cords, electrode holder and cables in are in good shape and free of cuts, splices or
other defects. Contact a supervisor if you find a problem with the welder.
b. Ensure ground clamp is in good condition and all connections are robust.
c. Do not touch electrode.
d. Electromagnetic Fields (1)

Electric current flowing through any conductor causes localized electric and magnetic fields (EMF).
Welding current creates an EMF field around the welding circuit and welding equipment. EMF fields
may interfere with some medical implants, e.g. pacemakers. Protective measures for persons wearing
medical implants have to be taken. For example, restrict access for passersby or conduct individual
risk assessment for welders. All welders should use the following procedures in order to minimize
exposure to EMF fields from the welding circuit:
1. Keep cables close together by twisting or taping them, or using a cable cover.
2. Do not place your body between welding cables. Arrange cables to one side and away from the
operator.
3. Do not coil or drape cables around your body.
4. Keep head and trunk as far away from the equipment in the welding circuit as possible.
5. Connect work clamp to workpiece as close to the weld as possible.
6. Do not work next to, sit or lean on the welding power source.

About Implanted Medical Devices:

Implanted Medical Device wearers should consult their doctor and the device manufacturer before
performing or going near arc welding, spot welding, gouging, plasma arc cutting, or induction heating
operations.
(1) Content from Miller Electric Mfg, http://www.millerwelds.com/pdf/safety/som_eng_200704.pdf

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ADDITIONAL WELDING CONSIDERATIONS
7. College of Engineering Student Shop Welding Processes
There are many types of welding processes. The College of Engineering student shop has the flowing
types of welders: arc, GMAW/MIG and GTAW/TIG. Note that MIG and TIG are a form of arc welding.
While each have their own strengths and weaknesses
Content below is taken from the respective Wikipedia link for each welding process.

a. Arc Welding (source: http://en.wikipedia.org/wiki/Arc_welding)

Arc welding is a type of welding that uses a welding power supply to create an electric arc between an
electrode and the base material to melt the metals at the welding point. They can use either direct
(DC) or alternating (AC) current, and consumable or non-consumable electrodes. The welding region
is usually protected by some type of shielding gas, vapor, and/or slag.

b. GMAW / MIG (source: http://en.wikipedia.org/wiki/Mig_welding)

Gas metal arc welding (GMAW), sometimes referred to by its subtypes metal inert gas (MIG) welding
or metal active gas (MAG) welding, is a semi-automatic or automatic arc welding process in which a
continuous and consumable wire electrode and a shielding gas are fed through a welding gun. A
constant voltage, direct current power source is most commonly used with GMAW, but constant
current systems, as well as alternating current, can be used. There are four primary methods of metal
transfer in GMAW, called globular, short-circuiting, spray, and pulsed-spray, each of which has
distinct properties and corresponding advantages and limitations.

Originally developed for welding aluminum and other non-ferrous materials in the 1940s, GMAW was
soon applied to steels because it allowed for lower welding time compared to other welding
processes. The cost of inert gas limited its use in steels until several years later, when the use of
semi-inert gases such as carbon dioxide became common. Further developments during the 1950s
and 1960s gave the process more versatility and as a result, it became a highly used industrial
process. Today, GMAW is the most common industrial welding process, preferred for its versatility,
speed and the relative ease of adapting the process to robotic automation. Unlike welding processes
that do not employ a shielding gas, such as shielded metal arc welding, it is rarely used outdoors or in
other areas of air volatility. A related process, flux cored arc welding, often does not utilize a shielding
gas, instead employing a hollow electrode wire that is filled with flux on the inside.

c. GTAW / TIG (source: http://en.wikipedia.org/wiki/Gas_tungsten_arc_welding)

Gas tungsten arc welding (GTAW), also known as tungsten inert gas (TIG) welding, is an arc welding
process that uses a nonconsumable tungsten electrode to produce the weld. The weld area is
protected from atmospheric contamination by a shielding gas (usually an inert gas such as argon),
and a filler metal is normally used, though some welds, known as autogenous welds, do not require it.
A constant-current welding power supply produces energy which is conducted across the arc through
a column of highly ionized gas and metal vapors known as a plasma.

GTAW is most commonly used to weld thin sections of stainless steel and non-ferrous metals such as
aluminum, magnesium, and copper alloys. The process grants the operator greater control over the
weld than competing processes such as shielded metal arc welding and gas metal arc welding,
allowing for stronger, higher quality welds. However, GTAW is comparatively more complex and

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difficult to master, and furthermore, it is significantly slower than most other welding techniques. A
related process, plasma arc welding, uses a slightly different welding torch to create a more focused
welding arc and as a result is often automated.

8. Hands-On Welding Training

In general, welding requires a significant amount of practice before it can be done competently. Please
discuss with the shop supervisor you general welding goals so that they can sit down with you and
provided the initial training experience needed.
Also, please understand that you may need considerable practice before you are capable of making
structurally sound (important!) and/or aesthetically attractive (less important) welds. Plan accordingly.
9. Structural Welding

When welding in a structural application, great care must be taken to ensure that the weld had the
integrity needed and the base material has not been compromised by the welding process.
Unless one has significant experience in welding, structural applications should be left for more
experienced welders. The shop supervisor can help you find that expertise if you or others in your group
do not have the welding skill and experience needed for your structural project.

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