One of the most popular and common types of welding in use today is electric arc welding. However, the average layperson walking down the street knows very little about this welding process, except for the blinding lights of the construction sites they may walk past during rush hour. Welding is basically just the fusing process of joining metals. The metals are simply melted together and fused into one by high temperatures. If done correctly, welding will make a joint of two pieces of metal as strong as a single solid piece of metal. Welded joints are superior to glued joints because through the welding process, the metals actually melt together rather than using the adhesive properties of glue to hold them together.
The key concept of welding is that a heat source is required to fuse the metals together. There are several welding methods, with electric arc welding being one of the most popular. The term arc welding comes from the fact that an electric arc is created to generate intense heat. This arc is formed between the metal being worked on and the electrode attached to the arc welder. The electrode rod moves along the joint and is melted by the arc. The rod has two purposes. One is to help create the arc, and the other is to create filler material as it melts.
The heart of arc welding is creating the circuit. An arc welder requires a power source that produces either AC or DC current. By connecting the cable from the arc welder to the metal, the metal part you are trying to weld becomes part of the circuit. Another hot cable is connected to an electrode held by the welder. As the electrode approaches the metal, an electric arc is created between the metal workpiece and the electrode. There is now a complete circuit between the arc welder and the metal. This process creates some very impressive temperatures. The tip of the arc can reach temperatures in excess of 6500º F. There is now enough heat to fuse the pieces of metal together and form a strong bond. To ignite the arc, the electrodes must be pressed against the metal and then pulled apart.
In addition to producing heat, the arc produces a very bright light. This light is dangerous to welders and those around the welding job site. You should not look directly into the arc without proper goggles. However, visible light is not the only danger. The electric arc emits infrared and ultraviolet light that is not visible to the naked eye. This is why welders wear auto-darkening welding caps. When the arc is struck, these helmets automatically darken to protect the welder's eyes from bright visible light, and the lens filters are designed to always block infrared and ultraviolet light, whether the lenses are darkened or not. Welders also erect welding blankets or shields to protect others in the work area who may not have proper goggles.
Despite these dangers, arc welding is a safe and reliable way to fuse metals together, and with some practice, anyone can do basic welding.
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