Jim's Cover Pass: Don’t know what to teach nonwelders about welding? Here’s a start

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Q: I am a welding training and development specialist, and I have been asked to teach welding to our maintenance personnel. What do you recommend for course content when teaching SMAW and GMAW processes?

The first thing that should be covered is welding safety. This should begin with using the proper PPE—selecting the correct welding lens shade based on the process and the amperage being used; wearing quality welding gloves and a welding jacket to provide protection from the heat, sparks, and arc; and wearing heavy jeans or work pants without any fraying.

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 the rated amperage and proper connections.

Last on the safety training agenda should be the welding environment. Help them understand that welding and cutting sparks can travel up to 35 ft., and that all flammable objects should be removed or covered in that welding zone. Perhaps a hot-work permit is required in the facility, along with a fire watch during and after welding.

The next topic that should be covered is general welding principles. They’ll need a basic understanding of electrical current and the difference between constant-current and constant-voltage power sources. They’ll need to know that SMAW uses constant current and GMAW uses constant voltage.

Include lessons on when to use direct current electrode positive (DCEP) and direct current electrode negative (DCEN)— that SMAW will usually use DCEP but sometimes DCEN or AC, and that GMAW will always use DCEP. Welding principles also should include proper electrode selection and an understanding of the AWS electrode numbering system.

Provide recommendations on which process should be chosen for various circumstances within the facility. The welding process that should be covered and practiced first may depend on which process is used predominately for maintenance at your facility. It really does not matter which you choose.

Spend time on the basic theories of each welding process. Include instructor demonstrations and directions along with several hours of hands-on practice in both a welding booth and on potential maintenance projects.

You did not mention training with the oxyfuel processes. For maintenance personnel, this topic should also be included. Again, safety principles, cylinder and torch equipment setup and selection, startup and shutdown procedures, and cutting practice are essential to become familiar with the process.

Finally, it is helpful to have the new crew members shadow those with experience for a period of time after the formal training is complete.