I. Processes & Techniques (20)
* Arc Welding: A welding process that uses an electric arc to generate heat for melting the base metal and filler metal.
* Brazing: Joining metals using a filler metal with a liquidus temperature below that of the base metals, but above 450°C (840°F).
* Butt Weld: A weld between two pieces of metal joined edge to edge.
* Fillet Weld: A weld joining two surfaces at an angle, typically 90 degrees.
* Fusion Welding: Welding processes that melt the base metal to create coalescence.
* Gas Metal Arc Welding (GMAW/MIG): An arc welding process using a continuous consumable wire electrode and a shielding gas.
* Gas Tungsten Arc Welding (GTAW/TIG): An arc welding process using a non-consumable tungsten electrode and a shielding gas.
* Lap Weld: A weld joining two pieces of metal overlapping each other.
* Plasma Arc Welding (PAW): An arc welding process using a constricted arc and plasma gas.
* Resistance Welding: Welding processes that use pressure and electric current to generate heat for welding.
* Shielded Metal Arc Welding (SMAW/Stick Welding): An arc welding process using a consumable covered electrode.
* Submerged Arc Welding (SAW): An arc welding process where the arc is submerged under a blanket of granular flux.
* Welding: A joining process that produces coalescence of materials by heating them to suitable temperatures with or without the application of pressure, or by the application of pressure alone, with or without the use of filler metal.
* Flash Welding: A resistance welding process that uses a flash of heat to prepare the surfaces for joining.
* Spot Welding: A resistance welding process used to join overlapping metal sheets at discrete points.
* Seam Welding: A resistance welding process producing a continuous weld along a joint.
* Solid State Welding: Welding processes where joining takes place without melting the base metal.
* Ultrasonic Welding: A solid-state welding process using high-frequency sound waves.
* Friction Welding: A solid-state welding process using friction to generate heat.
* Laser Beam Welding (LBW): A welding process using a highly focused laser beam as a heat source.
II. Equipment & Consumables (20)
* Electrode: A consumable or non-consumable component used to conduct current to the arc.
* Filler Metal: Metal added during welding to fill the joint.
* Flux: A substance used to prevent or dissolve oxides during welding.
* Gas Shielding: A gas or mixture of gases used to protect the weld area from atmospheric contamination.
* Inverter: A power source that converts AC to DC for welding.
* Nozzle: A component that directs the shielding gas and/or the electrode.
* Welding Helmet: Protective gear worn to shield the eyes and face from arc radiation.
* Welding Leads: Cables that carry current to the welding equipment.
* Ground Clamp: A clamp used to connect the work piece to the welding circuit.
* Electrode Holder: A tool used to hold the welding electrode.
* Wire Feed: A mechanism that feeds the welding wire in GMAW/MIG welding.
* Regulator: A device used to control the flow of shielding gas.
* Welding Machine: A device that provides the power for welding.
* Tungsten Electrode: A non-consumable electrode used in GTAW/TIG welding.
* Ceramic Nozzle: A nozzle made of ceramic material, often used in GTAW/TIG.
* Backing Strip: A piece of metal placed behind the joint to support the weld.
* Consumable Insert: A preformed piece of filler metal placed in the joint before welding.
* Welding Gun: A handheld tool used in GMAW/MIG welding.
* Stinger: Another term for the electrode holder.
* Welding Blanket: A fire-resistant blanket used to protect the work area.
III. Weld Characteristics & Defects (20)
* Bead: The metal deposited during one pass of welding.
* Crater: A depression at the end of a weld bead.
* Fusion Zone: The area where the base metal and filler metal have melted and joined.
* Heat-Affected Zone (HAZ): The area of the base metal affected by the heat of welding.
* Penetration: The depth to which the weld metal fuses into the base metal.
* Porosity: Small voids or holes in the weld metal.
* Slag: Non-metallic inclusions in the weld metal.
* Undercut: A groove melted into the base metal at the toe of the weld.
* Overlap: Weld metal that extends beyond the toe of the weld.
* Crack: A fracture in the weld metal or HAZ.
* Lack of Fusion: Failure of the weld metal to fuse with the base metal.
* Lack of Penetration: Insufficient penetration of the weld metal into the base metal.
* Inclusion: Foreign material trapped in the weld metal.
* Distortion: Changes in the shape of the work piece due to welding.
* Residual Stress: Stresses remaining in the weldment after welding.
* Weld Toe: The junction between the weld face and the base metal.
* Weld Root: The point where the two pieces being welded come closest together.
* Weld Face: The exposed surface of the weld.
* Reinforcement: Weld metal added in excess of the required thickness.
* Concavity: The inward curvature of the weld face.
IV. Joint Types & Positions (15)
* Butt Joint: A joint between two pieces of metal joined edge to edge.
* T-Joint: A joint where two pieces of metal meet at a 90-degree angle, forming a “T” shape.
* Corner Joint: A joint where two pieces of metal meet at an angle to form a corner.
* Edge Joint: A joint where two pieces of metal are joined at their edges.
* Lap Joint: A joint where two pieces of metal overlap.
* Groove Weld: A weld made in a groove between two pieces of metal.
* Fillet Weld: A weld joining two surfaces at an angle, typically 90 degrees.
* Plug Weld: A weld made through a hole in one piece of metal to join it to another.
* Slot Weld: Similar to a plug weld, but made in an elongated hole.
* Flat Position: Welding performed with the work piece positioned horizontally.
* Horizontal Position: Welding performed on a vertical surface.
* Vertical Position: Welding performed on a vertical surface.
* Overhead Position: Welding performed with the work piece positioned above the welder.
* Pipe Welding: Specialized welding for joining pipes.
* Structural Welding: Welding of structural steel components.
V. Safety & Other Terms (25)
* Arc Flash: A dangerous release of energy produced by an electric arc.
* Fumes: Airborne particles and gases produced during welding.
* PPE (Personal Protective Equipment): Equipment worn to minimize exposure to hazards.
* Welding Procedure Specification (WPS): A document outlining the specific parameters for a welding operation.
* Welding Qualification Test (WQT): A test to assess a welder’s ability to produce sound welds.
* AWS (American Welding Society): A professional organization that develops welding standards.
* ASME (American Society of Mechanical Engineers): A professional organization that develops codes and standards, including those for welding.
* Code: A set of rules and regulations.
* Standard: A set of specifications or guidelines.
* Metallurgy: The study of metals and their properties.
* Preheat: Heating the base metal before welding.
* Post-weld Heat Treatment (PWHT): Applying heat to the weldment after welding.
* Stress Relieving: Reducing residual stresses in the weldment.
* Hardfacing: Applying a hard wear-resistant material to a surface by welding.
* Cladding: Applying a layer of corrosion-resistant material to a base metal by welding.
* Backing: Material placed behind the weld joint
* Pass: A single progression of welding along a joint.
* Root Pass: The first weld pass made at the root of the joint.
* Hot Pass: A weld pass made immediately after the root pass, while the joint is still hot.
* Cover Pass: The final weld pass(es) made to complete the weld.
* Stringer Bead: A weld bead made with minimal weaving motion.
* Weave Bead: A weld bead made with a wide weaving motion.
* Travel Speed: The rate at which the welding electrode is moved along the joint.
* Amperage: The amount of current flowing through the welding circuit.
* Voltage: The electrical potential difference across the welding arc.