Topic outline

  • General

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  • Incase You Didn't Read the Intro

    • So you are here. Whether it is your first time or your second, I would like to welcome you to E-Learn Malawi, and specifically to the Introduction to Welding course.

      Firstly, what do you think welding is?

      Most likely you defined it in a simple way, something like joining two pieces of metal together. That is not wrong, but let us make it more accurate.

      Welding is the process of joining two or more pieces of metal or thermoplastic materials by applying heat, pressure, or both, so that the materials melt and fuse together to form a strong permanent joint.

      But here is the thing. Not all welding is the same. There are different types of welding, and each one uses different tools, materials, and techniques.

       

       


      Disclaimer: We do not own the video used and it has been used strictly for education al purposes.


  • Types Of Welding

    • TYPES OF WELDING

      1. Stick Welding (SMAW – Shielded Metal Arc Welding)

      This is one of the most common and widely used welding methods.

      Materials Needed

      • Welding machine (power source)

      • Electrode holder

      • Flux-coated welding rods

      • Ground clamp

      • Welding helmet and gloves

      • Metal workpieces

      Advantages

      • Equipment is relatively affordable

      • Works well outdoors and in windy conditions

      • Can weld dirty, rusty, or painted metals

      • Portable and widely used for repairs

      Disadvantages

      • Welding rods need to be replaced often

      • Produces slag that must be cleaned after welding

      • Slower than some modern welding processes

      • Requires good skill and coordination


      2. MIG Welding (Metal Inert Gas Welding)

      MIG welding uses a continuously fed wire electrode and shielding gas to protect the weld.

      Materials Needed

      • MIG welding machine

      • Welding gun

      • Wire electrode spool

      • Shielding gas cylinder (argon or mixed gases)

      • Ground clamp

      • Welding helmet and protective clothing

      Advantages

      • Faster welding process

      • Easier for beginners to learn

      • Produces cleaner welds with less slag

      • Good for many metals like steel and aluminum

      Disadvantages

      • Equipment and gas can be expensive

      • Shielding gas can be affected by wind outdoors

      • Requires clean metal surfaces before welding


      3. TIG Welding (Tungsten Inert Gas Welding)

      TIG welding uses a non-consumable tungsten electrode to create a precise arc.

      Materials Needed

      • TIG welding machine

      • Tungsten electrode

      • Filler metal rods

      • Shielding gas (usually argon)

      • Welding torch

      • Protective gear

      Advantages

      • Very clean and precise welds

      • Excellent for thin metals

      • Produces high quality weld appearance

      • Allows precise heat control

      Disadvantages

      • Slower process compared to other methods

      • Requires higher skill to perform properly

      • Equipment and setup cost can be higher



  • Tools Of The Trade

    • Before you start welding, you need the right tools. You do not need a massive industrial workshop to begin. A small, basic setup can already get you working on simple projects like gates, metal repairs, frames, and small fabrication work.

      Here are the main tools you need to start.

       

       

      Basic Welding Tools

      • Welding machine
        This is the main tool that produces the electric current needed to create the welding arc. For beginners, a small stick welding machine is usually the easiest and most affordable option.

      • Electrode holder
        This is the clamp that holds the welding rod while you work.

      • Ground clamp
        This connects the welding machine to the metal you are working on to complete the electrical circuit.

      • Welding rods (electrodes)
        These are the metal rods that melt and form the weld joint.


      Safety Tools

      Safety is not optional in welding.

      • Welding helmet to protect your eyes from the intense arc light

      • Welding gloves to protect your hands from heat and sparks

      • Protective clothing or apron to protect your body from burns


      Supporting Workshop Tools

      These tools make the job easier and more precise.

      • Angle grinder for cleaning metal, smoothing welds, and cutting

      • Wire brush for removing slag and cleaning weld joints

      • Hammer or chipping hammer for removing slag after stick welding

      • Measuring tape to ensure accurate cuts and joints

      • Clamps to hold metal pieces in position while welding


      Power and Workspace

      You also need:

      • A stable power supply for the welding machine

      • A strong metal work table or surface

      • Good ventilation to reduce smoke exposure


      Discaimer: We do not own the video used. It has been used for Education Purposes exclusively

  • The Actual Welding Process

    • Now we move to the actual welding process itself. This is a separate practical topic because the techniques can differ depending on the type of welding being used.

       

       

      Basic Welding Steps

      • Prepare and clean the metal surfaces

      • Clamp or position the metal pieces securely

      • Connect the ground clamp to the metal

      • Select the correct welding rod or wire

      • Set the appropriate current or voltage on the machine

      • Start the arc between the electrode and the metal

      • Move steadily along the joint to create the weld bead

      • Allow the weld to cool naturally

      • Clean the weld if slag or residue is present

      These steps may vary slightly depending on whether you are using MIG, TIG, or stick welding, but the overall concept remains similar.


      Disclaimer: we do not own the video used. It has been used strictly for educational purposes


  • Safety, Do’s and Don’ts in Welding