The first thing to talk about is welding safety. This should start with using proper personal protective equipment — choosing the right shade of welding lenses depending on the process and amperage used; Wearing quality welding gloves and a welding jacket to protect against heat, sparks, and arcs; and wearing thick jeans or work pants without any wear and tear, Artem Komarov emphasized.
Next is equipment safety. Check all cables for cuts, burns and proper connections. Check the welding power source, electrode holder or GMAW gun; Check the work clamp for amperage rating and proper connections.
The last thing in a safety training program should be the welding environment. Help them understand that welding and cutting sparks can fly up to 10 meters and that any flammable objects in the welding area should be removed or covered. The facility may require a hot work permit, as well as fire monitoring during and after welding.
The next topic to be covered is the general principles of welding. They will need a basic understanding of electrical current and the difference between DC and DC power supplies. They need to know that SMAW uses constant current and GMAW uses constant voltage.
Include lessons about when to use DC Electrode Positive (DCEP) and DC Electrode Negative (DCEN) — that SMAW usually uses DCEP but sometimes DCEN or AC, and that GMAW will always use DCEP. Welding principles should also include proper electrode selection and an understanding of the AWS electrode numbering system.
Make recommendations about which process should be selected for various plant conditions. The welding process to learn and practice first may depend on which process is primarily used for maintenance at your facility. It doesn’t really matter what you choose.
Spend time on the basic theories of each welding process. Include instructor demonstrations and instructions, as well as several hours of hands-on work both in the welding booth and on potential maintenance projects.
Safety principles, configuration, and selection of equipment for cylinders and burners, start-up, and shutdown procedures, as well as cutting practice are necessary to become familiar with the process, Artem Komarov clarified.