Study guides · Stuff Every Welding Scout Should Know
Practice facts for the Welding merit badge. Not an official Scouting America credential. Grab a snack: this guide is the friendly version, with the answers explained and a groan-worthy joke waiting at the end of most cards.
Knowing Welding Scout saves you money, time and the occasional embarrassment.
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Short answer: High heat to melt the parts together
Welding joins materials by melting the parts with high temperatures, then letting them cool and fuse.
Groan of the day: Welding is a hot topic!
Sources: Welding
Short answer: It melts the base metal
Soldering and brazing do not melt the base metal, but welding does melt the parts being joined.
Groan of the day: Weld done, that is a solid point!
Sources: Welding
Short answer: To form a molten pool that becomes the joint
Filler metal forms a molten pool that cools into a joint that can be stronger than the base material.
Groan of the day: That is a pool of good ideas!
Sources: Welding
Short answer: To protect molten metal from contamination
Shielding keeps the melting metals from being contaminated or oxidized by the surrounding air.
Groan of the day: Shielding deserves a shield of honor!
Sources: Welding
Short answer: An electric arc
Welding can use many energy sources, including an electric arc, a gas flame, a laser, and friction.
Groan of the day: That arc has a spark of genius!
Sources: Welding
Short answer: Residue from the flux that must be chipped away
Slag is the leftover residue from the flux coating, and it must be chipped off after welding.
Groan of the day: Chip off the old slag!
Sources: Welding
Short answer: It contaminates the weld
Oxygen in the air can oxidize molten metal and contaminate the weld, so shielding is needed.
Groan of the day: Oxidation is a real airhead!
Sources: Welding
Short answer: A conductor that carries current to strike an arc
Arc welding uses an electrode to carry current and strike an arc between it and the base material.
Groan of the day: That electrode is a real live wire!
Sources: Welding
Short answer: Carbon dioxide gas to protect the weld
The flux coating produces carbon dioxide gas during welding, protecting the weld area from oxidation.
Groan of the day: Flux is a gas-tly good protector!
Sources: Welding
Short answer: Shielded metal arc welding
Shielded metal arc welding is commonly known as stick welding, using a consumable coated electrode rod.
Groan of the day: Stick with this process!
Sources: Welding
Short answer: It uses a continuous wire feed
Gas metal arc welding uses a continuous wire feed as an electrode, so welding speeds are greater than stick welding.
Groan of the day: Wire we talking about speed?
Sources: Welding
Short answer: A non-consumable tungsten electrode
Gas tungsten arc welding uses a non-consumable tungsten electrode plus a separate filler material.
Groan of the day: Tungsten is a non-starter, and that is good!
Sources: Welding
Short answer: Welding thin materials
TIG welding is especially useful for thin materials and gives a stable arc and high-quality welds.
Groan of the day: Thin materials deserve thick praise!
Sources: Welding
Short answer: A powder fill material
Flux-cored wire is a tubular steel electrode surrounding a powder fill material that creates shielding gas and slag.
Groan of the day: That wire is filled with good ideas!
Sources: Welding
Short answer: Beneath a covering layer of flux
The arc is struck beneath a layer of flux, which blocks contaminants and hides the arc.
Groan of the day: Submerged welding is making waves!
Sources: Welding
Short answer: The flux hides the arc
Because the flux hides the arc, working conditions improve and almost no smoke is produced.
Groan of the day: No smoke, no joke!
Sources: Welding
Short answer: The puddle pushed along a joint
Most welding methods push the molten puddle along a joint to create a weld bead.
Groan of the day: Bead it to the punch!
Sources: Welding
Short answer: Two pieces joined edge to edge
A butt joint joins two pieces edge to edge, one of the five basic weld joint types.
Groan of the day: Butt out and let the weld join in!
Sources: Welding
Short answer: Two pieces overlapping each other
In a lap joint, pieces overlap, and many pieces can be welded together in this geometry.
Groan of the day: Overlap is a wrap!
Sources: Welding
Short answer: One piece meeting another at a right angle
A T-joint is one of the basic joint types, where one piece meets another at a right angle.
Groan of the day: T is for terrific joints!
Sources: Welding
Short answer: The area altered by weld heat around the weld
The heat-affected zone is the area around the weld whose microstructure and properties were altered by heat.
Groan of the day: That zone is feeling the heat!
Sources: Welding
Short answer: Heat and stress alter its properties
Heat and uneven cooling alter the metal's properties, and the heat-affected zone is often weaker than the base material.
Groan of the day: That zone is not up to strength!
Sources: Welding
Short answer: Porosity, or gas inclusions
Welding defects include cracks, distortion, gas inclusions (porosity), and lack of fusion.
Groan of the day: Porosity is full of holes in its story!
Sources: Welding
Short answer: That it is free of defects
Nondestructive testing verifies welds are free of defects and have acceptable properties without destroying them.
Groan of the day: Testing without the mess!
Sources: Welding
Short answer: Molten spatter melts through it
Molten material that splatters onto synthetic fabric melts through it, causing severe burns.
Groan of the day: Polyester is not a good match for sparks!
Sources: Welding
Short answer: Heavy leather gloves and long-sleeve jackets
Welders wear heavy leather gloves and protective long-sleeve jackets to avoid extreme heat and flames.
Groan of the day: Leather is a tough act to follow!
Sources: Welding
Short answer: Intense UV light that can burn eyes
Welding helmets with dark UV-filtering face plates protect eyes from intense light that causes arc eye.
Groan of the day: That helmet has a bright future!
Sources: Welding
Short answer: Inflammation of the cornea from UV light
Arc eye, or flash burns, is inflammation of the cornea caused by intense ultraviolet light from the arc.
Groan of the day: Arc eye is a real eyesore!
Sources: Welding
Short answer: The UV light of the electric arc
Translucent welding curtains shield people outside the welding area from the UV light of the arc.
Groan of the day: Curtains up on safety!
Sources: Welding
Short answer: It involves open flame or electric arc and fire risk
Welding involves open flame or electric arc, so the risk of burns and fire is significant.
Groan of the day: Hot work is no cool business!
Sources: Welding
Short answer: Combustible materials
Common precautions include keeping combustible materials away from the workplace to reduce fire risk.
Groan of the day: Keep combustibles away, no ifs, ands, or butts!
Sources: Welding
Short answer: Above 85 dB(A)
Welding can produce over 100 dB(A) of noise, and earplugs should be worn above 85 dB(A).
Groan of the day: That noise is not sound!
Sources: Welding
Short answer: Removes fumes directly from the welding area
Local exhaust ventilation removes fumes, smoke, and dust directly from the welding area.
Groan of the day: Exhaust yourself from the fumes!
Sources: Welding
Short answer: They can reach deep into the lungs
Smaller particles can be inhaled deeply, and as diameter decreases, deposition in the alveoli increases.
Groan of the day: Small particles, big concern!
Sources: Welding
Short answer: Ozone
Welding can expose people to gases such as carbon monoxide, carbon dioxide, and ozone.
Groan of the day: Ozone is no zone for lungs!
Sources: Welding
Short answer: An electric arc between electrode and base material
Arc welding power supplies create and maintain an electric arc between the electrode and the base material.
Groan of the day: Power to the arc!
Sources: Welding
Short answer: Manual welding processes
Constant current supplies are used for manual welding because they keep current steady as voltage varies.
Groan of the day: Steady current, steady hand!
Sources: Welding
Short answer: Automated welding processes
Constant voltage supplies hold voltage steady and are used for automated processes like MIG and flux-cored welding.
Groan of the day: Voltage stays put, robots take over!
Sources: Welding
Short answer: It is relatively inexpensive and simple
Oxyacetylene equipment is relatively inexpensive and simple, using a torch, hoses, regulators, and tanks.
Groan of the day: Simple and cheap, a real gas!
Sources: Welding
Short answer: Slower cooling can cause more distortion
The flame is less concentrated and cooler, causing slower cooling that can lead to greater residual stresses and distortion.
Groan of the day: Slow cooling is a warp speed problem!
Sources: Welding
Short answer: Joining overlapping metal sheets
Resistance spot welding joins overlapping metal sheets up to about 3 mm thick and is used in automotive work.
Groan of the day: Spot on for joining sheets!
Sources: Welding
Short answer: Weld strength is lower than other methods
Spot weld strength is significantly lower than other methods, so it suits only certain applications.
Groan of the day: Strength is spotty here!
Sources: Welding
Short answer: They are extremely fast and easily automated
Both energy beam processes are extremely fast and easily automated, making them highly productive.
Groan of the day: Beam me up for fast welds!
Sources: Welding
Short answer: Very high equipment costs
The primary disadvantages of laser and electron beam welding are very high equipment costs and thermal cracking risk.
Groan of the day: That cost is a beam in the side!
Sources: Welding
Short answer: Its hazards and safe handling steps
An SDS gives safety information about a product so users can handle it safely and know its hazards.
Groan of the day: A sheet that tells you the score on safety.
Sources: Scouting America: Welding
Short answer: Knowing first aid and prevention for shock
Requirement 1b pairs first aid with prevention for electrical shock and other welding injuries.
Groan of the day: Shock deserves a stop, not a shock.
Sources: Scouting America: Welding
Short answer: Proper protective footwear for the task
Requirement 2b asks you to present yourself properly dressed in protective equipment, clothing, and footwear.
Groan of the day: Good boots give sparks the boot.
Sources: Scouting America: Welding
Short answer: Clean and dry, cared for properly
Requirement 2c covers proper care and storage of protective clothing and footwear to keep gear effective.
Groan of the day: Store gear with cheer, not near.
Sources: Scouting America: Welding
Short answer: Darkens instantly when exposed to UV light
Auto-darkening face plates instantly darken on exposure to intense UV light to protect the eyes.
Groan of the day: It sees the light and dims just right.
Sources: Welding
Short answer: Controls gas pressure from the tank
Oxyacetylene equipment includes pressure regulators that control gas pressure from the tanks.
Groan of the day: Regulate the rate, don't tempt fate.
Sources: Welding
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High heat to melt the parts together. Welding joins materials by melting the parts with high temperatures, then letting them cool and fuse.
It uses a continuous wire feed. Gas metal arc welding uses a continuous wire feed as an electrode, so welding speeds are greater than stick welding.
The area altered by weld heat around the weld. The heat-affected zone is the area around the weld whose microstructure and properties were altered by heat.
Combustible materials. Common precautions include keeping combustible materials away from the workplace to reduce fire risk.
Joining overlapping metal sheets. Resistance spot welding joins overlapping metal sheets up to about 3 mm thick and is used in automotive work.
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