Learn to Weld: Get Paid to Melt and Cut Steel With Fire

In its most basic form, welding is joining two pieces of metal together using heat. As the metal cools, the pieces join together. And sometimes, welders apply a filler material to strengthen the joint.

But that's not all:

Just to make things complicated, there are two exceptions to this very simple explanation.

But wait, there’s more.

What’s the difference between brazing, soldering, and welding?

Many people confuse welding, brazing, and soldering, so we want to clear up the confusion right away.

Here’s a breakdown of how they compare.

Welding

We've covered that.

Brazing

Image from Wikimedia Commons

Brazing doesn’t heat and melt the metals to form the joint, but instead uses a filler metal to create it. Using a torch to heat up the filler metal applied to the joint, the filler flows into all the nooks and crannies in the joint to form a strong bond.

This technique is perfect when you want to join two metals together that have different heating points.

Got it?

Soldering

Image from Wikimedia Commons

The process of soldering is similar to brazing in that instead of melting the materials in the joint, it uses fillers to surround and strengthen it. But when you solder something, the temperatures you use aren’t as hot.

Brazing uses temperatures of up to 800 degrees, while soldering melts at 390 degrees. People mostly use soldering to make electronic bonds like when working with circuit boards.

Okay, let’s move on.

The history of welding

You might think welding first began in the bronze ages.

And you’d be right.

The practice dates back to the Bronze Age when people used pressure welding to join lap joints together for circular boxes. People believe these boxes date back 2,000 years.

Then in the Iron Age, Egyptians and people living in the Eastern Mediterranean began welding iron pieces together.

Welding as people practice it today began happening in the nineteenth century.

Now, the specifics.

If you’re looking for a career where you can earn a good living and enjoy job security, you should learn to weld. The outcome for this profession is good, and those who can do it are in demand.

But here’s what you need to know:

Personal skills needed to become a welder

When you want to learn to weld, you need to consider whether or not you have the personal skills you need to succeed.

Welding is more than just holding a flame to metal and welding the pieces together. There are five types of welding you need to know about.

Oxy-fuel welding

Oxy-fuel welding is sometimes called gas welding, and it dates back to 1903.

Here's how to do it:

Welders connect a torch to two gas tanks. One of the tanks contains pure oxygen, and the other contains gas fuel such as acetylene. This fuel is what creates the flame that melts the metal.

Because the process also involves 100 percent oxygen, the temperature of the flame is about 6,332 degrees.

That’s a lot of heat.

And it melts the metal into a pool and creates the weld.

As simple as this sounds, most welders don’t use it anymore. But small business owners, hobbyists, or others who weld for their own purposes do.

Shielded Metal Arc Welding (SMAW)

Shielded Metal Arc Welding is also called Flux Shielded Arc Welding (FSAW)), Manual Metal Arc Welding (MMAW), or just plain old stick welding.

Yeah, we'll go with that one.

When performing stick welding, you won’t use a welding torch, but an electrode. This electrode is called a stick, which is how the method gets its nickname.

The electrode, which connects to a power supply, is covered by a shield, which is consumable. As you weld, the stick will get shorter and eventually, you will have to replace it.

Image from Pexels

You create an arc by touching the tock to the metal you want to weld, and then you withdraw it. You control the amperage via a foot pedal.

When you form the arc, the areas melts into a pool. Then, drops of the stick melt off and drop into the weld pool. This is your filler. Next, the shield coating starts to break down and forms a gas.

Here's the breakdown:

So, the first two steps create the weld, and the last one protects it. (It doesn’t allow the oxygen to hit the weld, which would oxidize it.)

At one time, this was the most popular method of welding, but welders are beginning to use other techniques instead. Welders use this method on iron, aluminum, steel, and copper alloys.

Gas Tungsten Arc Welding (TIG)

When performing TIG, the welder has to hold a welding torch that has a tungsten tip. This tip can withstand high temperatures, so it is not consumable.

The torch does two jobs:

Once the arc is created, you move the torch in a circular pattern, making the weld pool. Then using a rod dipped into the weld, you add the filler material. Continue this alternating pattern of putting the weld torch in and the filler rod out.

But beware:

Don’t withdraw the filler rod completely or you will take away the necessary gas shield. Otherwise, you will have oxidation.

Gas Metal Arc Welding (GMAW)

Gas Metal Arc Welding is also known as Metal Inert Gas welding (MIG). If you’re going to learn to weld, this is the best method for beginners because it’s the simplest.

Here’s how it works:

When the nozzle of the welding gun touches the base metal, it forms an arc. And that creates the filler metal for the weld pool. And then a shield gas comes out of the gun nozzle which protects the weld from absorbing water vapor or oxidizing. The welder controls the entire process with the trigger on the welding gun.

This is the most common type of welding, but it does come with pros and cons

Image by skeeze from Pixabay 

Flux-Cored Arc Welding (FCAW)

Flux-Cored Arc welding is similar to GMAW welding in that a continuously fed electrode provides the arc and filler material, but this type of welding creates its own shield gasses to protect the weld.

And that's not all:

The welding machine is smaller and less complicated, which makes it a great choice when you need to transport equipment to a job site.

But don’t use this machine for materials that are thinner than 20 gauge.

Photo by Terje Sollie from Pexels

When you learn to weld, you'll need to know how to make certain joint types to fit the project you’re working on.

Here are the five most common joints:

The butt joint

When forming a butt joint, you should lie the corners and same plane and join them at their edges.

The corner joint

To perform this joint, join the corners in a right angle and weld it at the center of that angle.

The lap joint

When forming two overlapping pieces together, it is called a lap joint.

The edge joint

You form this joint by ensuring the common edges of the metal are touching and then welding them together at that edge.

The T-joint

To create this joint, one joint should be at a right angle of the other one. The final result will look like a T.

Depending on the type of job you’re doing, your materials supply list will change. But here is a list of the most commonly used materials on welding jobs.

When you learn to weld, it’s important to know whether or not you’ve done it right. If you haven’t, the weld may not hold.

Let’s ensure that it does.

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One of the first questions people ask when wanting to learn to weld is how much they expect to make as a welder. After all, the job is dirty, difficult, and a little dangerous. So you would think the pay would be good, right?

And it is.

According to the Bureau of Labor’s most recent report, welders earn on average $40,240 a year. That breaks down to $19.32 an hour.

Not bad for doing something you love.

And growth in the industry looks good, too. The Bureau predicts a 6 percent rate of growth between now and 2026. It says the nation’s aging infrastructure will ensure that welders have work because they need to rebuild highways, buildings, and bridges.

But you have to figure your location into the factor because welders in some areas make more than others. For example, Alaska welders make some of the highest salaries in the nation, but that might be a long way off from friends and family.

Just remember this:

Your salary will depend on what type of welder you are and where you live.

The pre-weld inspection

Before you start welding, you will perform this inspection. You should check that the welding joint preparation is correct, and look at the parameters to ensure that that they’re right. When you do this, you will help prevent defective welding because you will understand the job as a whole before you begin.

This part of the process also includes the pre-weld setup and joint preparation.

For example:

A root opening that is too narrow or tight will cause improper root penetration. And openings that are too big will result in over penetration.

You should also go over and confirm your temperature and heating method, the availability of monitoring devices, and the presence of gas purging equipment.

Inspection while you’re welding

You need to be aware of the requirements and conditions surrounding the weld. Start by paying attention to your surroundings to ensure that wind, rain, or extreme temperatures won’t affect the weld.

When you're done that:

Look to ensure you meet the requirements of the weld. For instance, check the interpass cleaning methods and temperature controls, the settings, travel speed, what type of shielding you’ll use, the flow rate of the gas, and the welding sequence.

Post-weld inspection

Most welds go through non-destructive testing (NDT) method once complete, but it’s a good idea to do a visual test as well.

Here's what to look for:

Keep an eye out for undercut, overlap, undersized welds, cracks, surface pores, incomplete root penetration, underfill, excessive root penetration, burn through, and excessive reinforcement.

Are you convinced you want to learn to weld?

You need more deets.

Photo by rawpixel.com from Pexels

One of the first questions people ask when wanting to learn to weld is how much they expect to make as a welder. After all, the job is dirty, difficult, and a little dangerous. So you would think the pay would be good, right?

And it is.

According to the Bureau of Labor’s most recent report, welders earn on average $40,240 a year. That breaks down to $19.32 an hour.

Not bad for doing something you love.

And growth in the industry looks good, too. The Bureau predicts a 6 percent rate of growth between now and 2026. It says the nation’s aging infrastructure will ensure that welders have work because they need to rebuild highways, buildings, and bridges.

But you have to figure your location into the factor because welders in some areas make more than others. For example, Alaska welders make some of the highest salaries in the nation, but that might be a long way off from friends and family.

Just remember this:

Your salary will depend on what type of welder you are and where you live.

Are you ready to learn to weld?

If so, it’s time to take a look at the process. Welding is one of the highest paying blue collar jobs out there, but get this:

It doesn’t take a lot to become certified.

Here’s what you need to know.

Get your high school diploma

Image by Olichel Adamovich from Pixabay 

Your first step when you want to learn to weld is to get your high school diploma. And the classes you take while in high school can greatly help you as a welder.

For instance, if your high school offers classes in metal fabrication or welding, take them. And don’t sleep during your math and science classes because that knowledge will be crucial to your welding career.

Here's why:

When working as a welder, you will use geometry and algebra as you measure and calculate on the job. And your science will give you insight into how welding works.

School's important, kids.

Get a welder’s certificate or degree

Your next step is to get a welder’s certificate or a degree.

Let’s take a look at both.

You can get a certificate from a welding certificate program in 6 to 18 months. The classes are in person, and you will learn everything you need to know when working in the field. The prices vary, but you can expect to pay $3,500 to $20,000 for the certificate.

On the other hand:

If you would rather get a degree, you can spend two years working toward a welding technology associates degree. You’ll pay a little more for this type of education with costs ranging from $6,000 to $55,000.

And if you’re an overachiever, you can go to school for four years to earn a welding engineering bachelor’s degree.

Become an apprentice

Becoming an apprentice isn’t a requirement when you want to learn to weld, but it will give you a leg up when you begin applying for jobs.

Getting all the on-the-job-training that you can will not only make you a better welder, it could also result in a higher salary once you start looking for a welding job.

To find an apprenticeship, you have a couple of choices:

Some states offer welding apprenticeships, as do many companies who want to hire new welders on the job.

But your best bet is to do a little digging online.

Start by doing to the US Department of Labor’s apprenticeship.gov. There, you can enter your location, and then specify welder to perform a custom search for welding apprenticeships in your area.

If you don’t find any there, head on over to the Department of Labor’s other site, careeronestop.org and do the same thing. That site also lists welding apprenticeships.

Certified Welder (CW)

You can take this examination without having to meet any requirements. You will pay $35 to take the exam, and you can take it at an AWS accredited testing facility.

Certified Welding Inspector (CWI)

To take this examination, you will need to meet certain requirements such as having received education and worked in the field. If you are a member of AWS, you will pay $850 to take the exam, but if you’re not, plan on shelling out $1,065 to take it.

Senior Certified Welding Inspector (SCWI)

You will also have to meet certain education and work experience requirements to take this exam. The charge is the same as above.

Certified Welding Educator (CWE)

If you want to become a certified welding educator, you need to complete the certified welding educator application form, hold a part-time or full-time job as a teacher in a classroom, have a valid welding certification, and provide a letter that recommends you as being able and qualified to teach.

Not only that:

You will pay $634 for this exam if you’re a member, and $850 if you’re not.

Certified Welding Sales Representative (CWSR)

You'll have to meet a few requirements to take this exam and pay a $275 fee if you’re a member and a $355 fee if you’re not.

Image from Pexels

Are you ready to learn to weld?

If so, it’s time to take a look at the process. Welding is one of the highest paying blue collar jobs out there, but get this:

It doesn’t take a lot to become certified.

Here’s what you need to know.

​9 Tips to Stay Safe While Welding

Are you ready? Here they are:

1. Know your equipment

It’s important to understand how your welding machine operates to use it safely. Read the instruction manual and then refresh yourself with it every year or so. And if other people use the machine, make sure they have read it, too.

And if you lose the manual, contact the manufacturer or another one or search one out online.

2. Cover exposed skin

You’re working with flames and extreme heat, so it makes sense to cover any exposed skin to avoid becoming burned. In addition, avoid wearing clothing with open pockets or cuffs because sparks can fly in them and then smolder without you realizing it.

And for goodness sakes, don’t keep lighters or matches anywhere near you while you’re welding.

3. Wear the right gear

You must dress properly when welding to prevent accidents. Ideally, you need to wear safety gear such as a helmet, flame-resistant clothing, and gloves.

In the past, welders complained that welding jackets were too hot and cumbersome, but that’s no longer the case. Today’s manufacturers make lightweight clothing that is flame resistant that allows you to move freely while staying safe.

Gloves have come a long way, too. You can buy welding gloves that have ergonomically curved fingers specifically designed for welders.

Image by Emir Krasnić from Pixabay 

4. Select the right shoes

You need to protect your feet when welding because sparks can fly and burn them. That’s why you should always wear boots or high-top shoes made of leather.

If you wear the wrong kind of footwear, the sparks could land on them, and they will begin to smolder.

Ouch.

5. Ensure that you have fresh air

The last thing you need when you are trying to learn to weld is to breathe in toxic smoke and fumes.

To avoid this:

Make sure you set up an exhaust hood to clear away the shielding gasses and fumes. And know when you should use a respirator.a

6. Protect your eyes

If you weld without protecting your eyes, an arc flash could injure your eyes, causing you a lot of pain.

So get this:

Your helmet should have a filter shade to protect your face and eyes. And you should wear safety glasses, ear protection, and side shields underneath the helmet.

7. Put on the right helmet

Because you'll need to react in a split second during an arc flash, you should invest in a high-quality auto-darkening helmet. These helmets sense the arc electromagnetically and offer protection for your eyes.

Be sure to buy a helmet that meets the ANSI standards.

8. Work in a neat environment

If you weld in an area that is full of clutter, it can lead to accidents.

Instead, clean the area and only keep what is necessary to do the job in it. Your tools and equipment should stay organized in a way that allows you to find them quickly and easily.

9. Use boom-mounted wire feeders

If you want to add efficiency, flexibility, comfort, and a touch of safety to your weld station, think about using boom-mounted wire feeders. These feeders rotate 360 degrees and can move up and down to create a 24 or 32-foot diameter workspace.

That's pretty important.

Now let’s talk about the one question you’ve surely have in the back of your mind:

Will robots take over and eliminate welder jobs in the future?

Photo by Matan Segev from Pexels

For years people have speculated that robots are going to take over the workforce and leave people without jobs.

But the facts just don’t back that up.

In fact, the companies that use the most number of robots in their production lines are actually increasing the number of employees they have.

As it turns out:

Robots need humans to manage and maintain them, and experts say they don’t believe workplaces will run on robot power instead of humans anytime in the near future.

Photo by Min An from Pexels

Have you read enough that convinces you that when you learn to weld, you will gain a skill that makes you highly employable? While welders work blue collar jobs, they earn salaries that many white-collar employees and other professionals do.

But a welding job isn’t just a job.

Watch some of the videos in our article or talk to a welder you know: they love their jobs and wouldn’t dream of doing anything else.

Are you a welder, or do you want to learn to weld? Why not leave a comment below and start a conversation about this exciting topic?