Welder

Introduction

Welders join pieces of metal together by using intense heat. They are responsible for preparing the metal and looking after the tools that weld the metal together.

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Work Activities

Welders join pieces of metal together by using intense heat. The heat melts the metal to form a liquid pool, which then solidifies as a tight join. The welder may have to set up the pieces to be welded on a bench, workshop floor or construction site. These may be held in position by jigs or pre-positioned and tack welded by a plater, pipefitter or sheet metal worker.

Welders can use manual techniques to do a large amount of welding. They use an electric arc (the bright, hot area between the electrode tip and the metal) or a gas flame to melt the metal in the joint. There are four main manual welding processes. In manual metal arc welding (MMA), welders strike an arc between the metal rod and the work piece; both melt to form a weld pool. The flux covering on the rod melts, making a protection for the weld pool until it has cooled.

Oxy-acetylene (OA) relies on the combustion of oxygen and acetylene to form a very hot flame. In metal inert gas welding (MIG), welders use an inert gas to protect the arc and weld pool. Welders use the similar tungsten inert gas (TIG) method to join magnesium and aluminium.

Welders follow technical drawings or instructions, and work out the best position to adopt and the best angle to work at (kneeling, sitting, standing, lying or welding overhead). They may rehearse a difficult weld, going through the motions to be sure they can hold the position.

They prepare and clean the surface that they will weld. They fit the appropriate weld torch nozzle or electrode, set the current, switch on and strike the arc, and start to weld.

Welds may be horizontal or vertical, at an angle, on a curve, or encircling a big pipe. Welders may work from above, beside or below the weld and sometimes in very awkward and cramped spaces. Safety is vital to welding, so inspectors may check completed welds by using X-ray, ultrasonic or dye-testing techniques. If they discover cracks, porosity or other flaws, the welders have to ground out the weld and do the job again.

As well as manual techniques, some types of welding are mechanised or done by robots, especially in industries that produce items on a large scale, like the motor industry. Here, technicians set up the machines, which the welders then operate. There are other, more specialist welding processes like laser welding, electron beam welding and solid state welding.

At graduate level entry to The Welding Institute, engineers and technicians are involved in research and development departments, where they work on a very wide variety of projects. They help to solve problems in design, materials selection, production processes and systems, repairs and inspections.

They may research and develop high power lasers to help industry in welding, cutting and drilling. In materials research, materials engineers look at how metals behave (for example, in terms of corrosion), and the effects of welding on the properties and structure of materials.

They may work to improve the reliability of joining plastics; this is essential in the automotive and aerospace industries for example.

Welding engineers may act as consultants, giving advice to manufacturing industries on equipment and systems. Welders have helped to develop intelligent robotics for welding.

They usually wear protective clothing (helmets, overalls, apron, gloves, and tinted goggles). It can be very noisy, so welders may wear ear protectors.

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Personal Qualities and Skills

To be a manual welder, you must be able to work with great accuracy, have very steady hands and the ability to concentrate exclusively on the weld for the duration of a 'run' (up to five minutes).

Good eyesight and hearing (to detect variations in the buzz and crackle of the arc) are important. You need physical fitness to lift and carry equipment, climb ladders and crawl into cramped spaces.

You must be able to work without close supervision. You need to be able to follow technical instructions carefully, and follow safety procedures at all times.

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Pay and Opportunities

The pay rates given below are approximate.

Welders earn in the range of £290 - £330 a week, rising to £370 - £430. Top earners can make around £520 a week. Welders usually work a 39-hour week. Overtime, including Saturday working, may be available.

Welders work in manufacturing or construction concerned with metal fabrication, in heavy engineering and related industries such as shipbuilding/repair and engineering construction.

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Adult Opportunities

It is now illegal for any organisation to set age limits for entry to employment, education or training, unless they can show there is a real need to have these limits.

Some people enter after working in other jobs that involved some welding, for example, plating followed by a relevant part time course at college.

A knowledge of and/or qualifications in metalwork and technical drawing can be an advantage.

Modern Apprenticeships may be available in some areas.

• 6% of employees work on a temporary basis.

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New Developments

Some people working in this occupation may be involved in the green jobs sector in areas such as renewable energy or waste management.