Training ranges from a few weeks of school or on-the-job training for
low-skilled positions to several years of combined school and on-the-job
training for highly skilled jobs.
Welding is the most common way of permanently joining metal parts. In this
process, heat is applied to metal pieces, melting and fusing them to form a
permanent bond. Because of its strength, welding is used in shipbuilding,
automobile manufacturing and repair, aerospace applications, and thousands of
other manufacturing activities. Welding also is used to join beams when
constructing buildings, bridges, and other structures, and to join pipes in
pipelines, power plants, and refineries.
Welders use many types of welding equipment set up in a variety of
positions, such as flat, vertical, horizontal, and overhead. They may perform
manual welding, in which the work is entirely controlled by the welder, or
semiautomatic welding, in which the welder uses machinery, such as a wire
feeder, to perform welding tasks.
Arc welding is the most common type of welding. Standard arc welding
involves two large metal alligator clips that carry a strong electrical current.
One clip is attached to any part of the workpiece being welded. The second clip
is connected to a thin welding rod. When the rod touches the workpiece, a
powerful electrical circuit is created. The massive heat created by the
electrical current causes both the workpiece and the steel core of the rod to
melt together, cooling quickly to form a solid bond. During welding, the flux
that surrounds the rod’s core vaporizes, forming an inert gas that serves to
protect the weld from atmospheric elements that might weaken it. Welding speed
is important. Variations in speed can change the amount of flux applied,
weakening the weld, or weakening the surrounding metal by increasing heat
exposure.
Two common but advanced types of welding are Gas Tungsten Arc (TIG) and Gas
Metal Arc (MIG) welding. TIG welding often is used with stainless steel or
aluminum. While TIG uses welding rods, MIG uses a spool of continuously fed
wire, which allows the welder to join longer stretches of metal without stopping
to replace the rod. In TIG welding, the welder holds the welding rod in one hand
and an electric torch in the other hand. The torch is used to simultaneously
melt the rod and the workpiece. In MIG welding, the welder holds the wire
feeder, which functions like the alligator clip in arc welding. Instead of using
gas flux surrounding the rod, TIG and MIG protect the initial weld from the
environment by blowing inert gas onto the weld.
Like arc welding, soldering and brazing use molten metal to join two pieces
of metal. However, the metal added during the process has a melting point lower
than that of the workpiece, so only the added metal is melted, not the workpiece.
Soldering uses metals with a melting point below 800 degrees Fahrenheit; brazing
uses metals with a higher melting point. Because soldering and brazing do not
melt the workpiece, these processes normally do not create the distortions or
weaknesses in the workpiece that can occur with welding. Soldering commonly is
used to join electrical, electronic, and other small metal parts. Brazing
produces a stronger joint than does soldering, and often is used to join metals
other than steel, such as brass. Brazing can also be used to apply coatings to
parts to reduce wear and protect against corrosion.
Skilled welding, soldering, and brazing workers generally plan work from
drawings or specifications or use their knowledge of fluxes and base metals to
analyze the parts to be joined. These workers then select and set up welding
equipment, execute the planned welds, and examine welds to ensure that they meet
standards or specifications. Highly skilled welders often are trained to work
with a wide variety of materials in addition to steel, such as titanium,
aluminum, or plastics. Some welders have more limited duties, however. They
perform routine jobs that already have been planned and laid out and do not
require extensive knowledge of welding techniques.
Automated welding is used in an increasing number of production processes.
In these instances, a machine or robot performs the welding tasks while
monitored by a welding machine operator. Welding, soldering, and brazing machine
setters, operators, and tenders follow specified layouts, work orders, or
blueprints. Operators must load parts correctly and constantly monitor the
machine to ensure that it produces the desired bond.
The work of arc, plasma, and oxy-gas cutters is closely related to that of
welders. However, instead of joining metals, cutters use the heat from an
electric arc, a stream of ionized gas (plasma), or burning gases to cut and trim
metal objects to specific dimensions. Cutters also dismantle large objects, such
as ships, railroad cars, automobiles, buildings, or aircraft. Some operate and
monitor cutting machines similar to those used by welding machine operators.
Plasma cutting has been increasing in popularity because, unlike other methods,
it can cut a wide variety of metals, including stainless steel, aluminum, and
titanium.
Welding, soldering, and brazing workers often are exposed to a number of
hazards, including the intense light created by the arc, poisonous fumes, and
very hot materials. They wear safety shoes, goggles, hoods with protective
lenses, and other devices designed to prevent burns and eye injuries and to
protect them from falling objects. They normally work in well-ventilated areas
to limit their exposure to fumes. Automated welding, soldering, and brazing
machine operators are not exposed to as many dangers, however, and a face shield
or goggles usually provide adequate protection for these workers.
Welders and cutters may work outdoors, often in inclement weather, or
indoors, sometimes in a confined area designed to contain sparks and glare.
Outdoors, they may work on a scaffold or platform high off the ground. In
addition, they may be required to lift heavy objects and work in a variety of
awkward positions, while bending, stooping, or standing to perform work
overhead.
Although about 55 percent of welders, solderers, and brazers work a 40-hour
week, overtime is common, and some welders work up to 70 hours per week. Welders
also may work in shifts as long as 12 hours. Some welders, solderers, brazers,
and machine operators work in factories that operate around the clock,
necessitating shift work.
Welding, soldering, and brazing workers held about 452,000 jobs in 2002. Of
these jobs, about 2 of every 3 were found in manufacturing. Jobs were
concentrated in transportation equipment manufacturing (motor vehicle body and
parts and ship and boat building), machinery manufacturing (agriculture,
construction, and mining machinery), and architectural and structural metals
manufacturing. Most jobs for welding, soldering, and brazing machine setters,
operators, and tenders were found in the same manufacturing industries as
skilled welding, soldering, and brazing workers.
Training for welding, soldering, and brazing workers can range from a few
weeks of school or on-the-job training for low-skilled positions to several
years of combined school and on-the-job training for highly skilled jobs. Formal
training is available in high schools, vocational schools, and postsecondary
institutions, such as vocational-technical institutes, community colleges, and
private welding schools. The Armed Forces operate welding schools as well. Some
employers provide training. Courses in blueprint reading, shop mathematics,
mechanical drawing, physics, chemistry, and metallurgy are helpful. Knowledge of
computers is gaining importance, especially for welding, soldering, and brazing
machine operators, who are becoming responsible for the programming of
computer-controlled machines, including robots.
Some welders become certified, a process whereby the employer sends a worker
to an institution, such as an independent testing lab or technical school, to
weld a test specimen according to specific codes and standards required by the
employer. Testing procedures are based on the standards and codes set by one of
several industry associations with which the employer may be affiliated. If the
welding inspector at the examining institution determines that the worker has
performed according to the employer’s guidelines, the inspector will then
certify the welder being tested as able to work with a particular welding
procedure.
Welding, soldering, and brazing workers need good eyesight, hand-eye
coordination, and manual dexterity. They should be able to concentrate on
detailed work for long periods and be able to bend, stoop, and work in awkward
positions. In addition, welders increasingly need to be willing to receive
training and perform tasks in other production jobs.
Welders can advance to more skilled welding jobs with additional training
and experience. For example, they may become welding technicians, supervisors,
inspectors, or instructors. Some experienced welders open their own repair
shops.
Job prospects should be excellent, as many potential entrants who could be
welders may prefer to attend college or may prefer work that has more
comfortable working conditions. Employment of welding, soldering, and brazing
workers is expected to grow about as
fast as the average for all occupations over the 2002-12 period. In
addition, many openings will arise as workers retire or leave the occupation for
other reasons.
The major factor affecting employment of welders is the health of the
industries in which they work. Because almost every manufacturing industry uses
welding at some stage of manufacturing or in the repair and maintenance of
equipment, a strong economy will keep demand for welders high. A downturn
affecting industries such as auto manufacturing, construction, or petroleum,
however, would have a negative impact on the employment of welders in those
areas, and could cause some layoffs. Levels of government funding for
shipbuilding as well as for infrastructure repairs and improvements are expected
to be another important determinant of the future number of welding jobs.
Regardless of the state of the economy, the pressures to improve
productivity and hold down labor costs are leading many companies to invest more
in automation, especially computer-controlled and robotically-controlled welding
machinery. This will reduce the demand for some low-skilled welders, solderers,
and brazers because these simple, repetitive jobs are being automated. The
growing use of automation, however, should increase demand for welding,
soldering, and brazing machine setters, operators, and tenders. Welders working
on construction projects or in equipment repair will not be affected by
technology change to the same extent, because their jobs are not as easily
automated.
Technology is helping to improve welding, creating more uses for welding in
the workplace and expanding employment opportunities. For example, new ways are
being developed to bond dissimilar materials and nonmetallic materials, such as
plastics, composites, and new alloys. Also, laser beam and electron beam
welding, new fluxes, and other new technologies and techniques are improving the
results of welding, making it useful in a wider assortment of applications.
Improvements in technology have also boosted welding productivity, making
welding more competitive with other methods of joining materials.
Median hourly earnings of welders, cutters, solderers, and brazers were
$14.02 in 2002. The middle 50 percent earned between $11.41 and $17.34. The
lowest 10 percent had earnings of less than $9.41, while the top 10 percent
earned over $21.79. The range of earnings of welders reflects the wide range of
skill levels. Median hourly earnings in the industries employing the largest
numbers of welders, cutters, solderers, and brazers in 2002 were:
Motor vehicle parts manufacturing
$16.02
Agriculture, construction, and mining machinery manufacturing
13.74
Architectural and structural metals manufacturing
13.34
Commercial and industrial machinery and equipment (except
automotive and electronic) repair and maintenance
13.06
Motor vehicle body and trailer manufacturing
12.83
Median hourly earnings of welding, soldering, and brazing machine setters,
operators, and tenders were $13.90 in 2002. The middle 50 percent earned between
$11.22 and $17.77. The lowest 10 percent had earnings of less than $9.36, while
the top 10 percent earned over $24.60. Median hourly earnings in motor vehicle
parts manufacturing, the industry employing the largest numbers of welding
machine operators in 2002 were $18.29.
Many welders belong to unions. Among these are the International Association
of Machinists and Aerospace Workers; the International Brotherhood of
Boilermakers, Iron Ship Builders, Blacksmiths, Forgers and Helpers; the
International Union, United Automobile, Aerospace and Agricultural Implement
Workers of America; the United Association of Journeymen and Apprentices of the
Plumbing, Pipefitting, Sprinkler Fitting Industry of the United States and
Canada; and the United Electrical, Radio, and Machine Workers of America.
Links to non-BLS Internet sites are provided for your convenience
and do not constitute an endorsement.
For information on training opportunities and jobs for welding, soldering,
and brazing workers, contact local employers, the local office of the State
employment service, or schools providing welding, soldering, or brazing
training.
Information on careers and educational opportunities in welding is available
from:
Suggested citation: Bureau of Labor Statistics, U.S.
Department of Labor, Occupational Outlook Handbook, 2004-05
Edition,
Welding, Soldering, and Brazing Workers
, on the Internet at http://www.bls.gov/oco/
ocos226.htm
(visited January 27, 2005).
Last Modified Date: February 27, 2004
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