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Training Welders to Improve Quality and Productivity in Industries

The welding training in the companies needs to train the welders in the early stages to instill good habits to prepare them to create a good quality weld and improve operational productivity. It also helps the welders to gain the confidence they need to become increasingly proficient for his future.

Following are a few important points for training the welders to improve their skill and stay safe in the welding training process.
Safety a Priority Habit: The welders need to protect themselves from the heat and electricity generated from welding process with personal protective equipment, The arc is dangerous to skin and eyes, so heat resistant gloves, safety glasses, helmet, and jacket with flame resistant clothes and safety shoes add them to safety need of the welders. Take care of the ventilation to keep the umes and gases at the permissible level. Trained the welder to keep his head out of welding fumes. The welders should use the instruction of the manufacturers and safety rules of the company judiciously. Routine checkup in welding training for connections etc should always be while standing on a rubber mat or dry board to minimize the possibility of electrical shock.
Cleanliness a Habit: The wiping off the base material with a clean and dry cloth will be sufficient to make flawless welding during welding training in most of the cases. The dirt, gases, and oil can enter the weld pool easily to make the weld very poor and costly rework. However, welding on steel requires the use of a stainless steel wire brush to clean out the joint before welding to remove the dirt and oxides from the surface.
Proper Installation of the Consumables: The electrical current should flow smoothly to gain a good quality of the welding. The welder should always use the instruction manual to install the consumables properly like diffuser, nozzles, contact tips airtight to make the circuit conductive for the electric current in a GMAW welding operation. Good connections help to prevent weld defects, support consistent productivity and reduce the risk of consumable failure

Follow Welding Procedure: The welding procedures are the recipe determined very carefully by experts and ensure to create consistent welding and should be followed at all the times. The recommended parameters are capable to produce the desired results by adjusting the shielding gas mixture, flow rate, voltage, and ampere ranges. These procedures also provide information on type and diameter of filler material; to use, as well as proper wire feed speed in case of GMAW.

Importance of Filler metals: The storing of filler metals is very important or welders. They should wear clean gloves when handling filler metals and store in a clean and dry environment. They should be familiar with the attributes of various types of wires and techniques welding with each type of filler metal. They should learn whether filler metals need a push or pull technique. They should be aware of the manufacturer’s specification sheet and all the recommendations.
Stay Cool:  The cool and comfortable behavior of welder during welding training help to lessen the chance of injuries associated with repetitive movements and reduce the fatigue. They should learn material handling, and try to improve the ergonomics of the workplace. The more involvement of welder can help to ensure greater safety compliance and lower worker’s compensation cost for injuries.
Knowledge of Material Properties: The mechanical and chemical properties of every metal are different and welder should understand the difference between material particularly how they react to heating and cooling. Many metals require pre and post heat treatments to control cooling rate and prevent cracking. If welders are aware of these attributes, they will be better prepared to make necessary changes during the welding process.

 Visual Inspection of the Weld: The accurate visual inspection of a completed weld is the first step toward quality control. This is a quickest and least expensive method of inspection to detect weld defects like porosity. The other defects which a welder can detect are, identification of lack of penetration, excessive penetration, and undercutting which is characterized by a notch in the base material are the commonest defects which can be detected.

Proper Maintenance: Every part of the welding system from the power source to gun and consumables requires maintenance to keep it operating effectively and efficiently. They should be trained for the preventive maintenance for the better result with the welding system. The regular checking of connections throughout the length of their gun as tight and secure is important and visually inspecting the tips and nozzles and replacing it may be required. The regular replacement of regulator, cables, the hose may be required if the damage is detected.

Train to Troubleshoot: A key skill is to identify and rectify the problem as quickly as possible to reduce the downtime and directly contribute to good weld quality and productivity and reduce the cost associated with rework. The adjustment of gas flow and leaking of gas detection can lead to solving the problem of porosity. They should know the adjustment in voltage and amperage settings to counter the issue of lack of penetration, excessive penetration, and undercutting, etc.

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