БЮДЖЕТНОЕ ПРОФЕССИОНАЛЬНОЕ ОБРАЗОВАТЕЛЬНОЕ УЧРЕЖДЕНИЕ

ОМСКОЙ ОБЛАСТИ

«ОМСКИЙ АВИАЦИОННЫЙ КОЛЛЕДЖ ИМЕНИ Н.Е.ЖУКОВСКОГО»

Шаги к мастерству сварщика: практические упражнения

Составители:

Антонова О.Н.

Маслакова Л.М.

2025

Пояснительная записка

Данный сборник разработан в целях повышения профессиональной компетентности

студентов и специалистов, обучающихся по специальности «Сварочное производство»

учебной дисциплины Иностранный язык.

Предназначен для формирования и развития навыков владения профессиональной

лексикой и терминологией на Иностранном языке, необходимой в сфере сварочного

производства.

Цели сборника:



Расширение профессионального словарного запаса;



Ознакомление с специфической лексикой и фразеологией по сварке;



Формирование навыков чтения технической документации на английском языке;



Развитие навыков устной и письменной коммуникации в профессиональной сфере.

Структура сборника включает в себя различные виды упражнений:

лексические задания,

перевод технических текстов,

составление диалогов, а также практические ситуации, моделирующие рабочие сценарии.

Практическое

использование

данного

сборника

способствует

улучшению

уровня

английского языка в профессиональной сфере, что является важным условием для

успешной реализации современных технологий сварочного производства и повышения

конкурентоспособности специалистов.

Разработан в соответствии с программой профессиональной подготовки и требованиями к

знанию Иностранного языка в области сварочного производства.

Unit 1

Welding Equipment

Welding equipment constitutes a crucial component of modern manufacturing, construction, and

repair industries.

The technological evolution of welding tools has significantly enhanced efficiency, safety, and

precision in joining metals and thermoplastics.

Advanced welding systems incorporate sophisticated features such as programmable controls,

automatic feeders, and real-time monitoring, enabling operators to achieve high-quality welds

with minimal defects.

The core of welding technology lies in various power sources, including arc welders, MIG

(Metal Inert Gas), TIG (Tungsten Inert Gas), and plasma cutting machines.

Each type of equipment is designed to suit specific applications, material types, and thicknesses.

For instance, MIG welders are favored for their speed and ease of use in industrial settings, while

TIG welders are preferred for precision work on thin materials.

Modern welding devices also emphasize safety features such as automatic shut-off, protective

enclosures, and advanced ventilation systems to minimize exposure to harmful fumes and

radiation.

The choice of welding consumables—such as electrodes, filler metals, and shielding gases—is

equally vital, impacting the durability and strength of welds.

In addition to portable and stationary units, robotic welding systems have revolutionized

production lines, offering unparalleled consistency and productivity.

These automated systems require specialized programming and maintenance but deliver high-

precision results that are difficult to replicate manually.

The maintenance and calibration of welding equipment are critical to ensure optimal

performance, prevent accidents, and extend the lifespan of the machines.

Proper training for operators on equipment handling, safety protocols, and troubleshooting is

indispensable.

As industries move toward Industry 4.0, integrating IoT (Internet of Things) sensors and data

analytics into welding systems is becoming increasingly common, allowing predictive

maintenance and process optimization.

In conclusion, the continuous development of welding technology and equipment plays a pivotal

role in advancing manufacturing capabilities, ensuring safety, and improving the quality of

welded products across various sectors.

Exercise 1: Vocabulary in Context (Choose the correct word to complete each sentence)

Words: automation, calibration, consumables, precision, safety, efficiency, monitoring,

durability, maintenance, features, productivity, quality, safety, technology, equipment

1 Modern welding __________ often include advanced sensors for real-time __________.

2 Proper __________ of welding machines is essential to ensure consistent welds.

3 The use of high-quality __________ such as electrodes and shielding gases directly affects the

__________ of welds.

4 Automated welding systems significantly increase __________ on production lines.

5 Safety __________ like protective shields and ventilation are vital in welding environments.

6 The __________ of welding equipment can be greatly improved with regular inspections.

7 Advanced welding __________ incorporate programmable controls and automatic feeding

systems.

8 The __________ of welds depends on both the skill of the operator and the capabilities of the

__________.

9 Robotic welding enhances __________ by reducing human error.

10 The development of new __________ has led to better energy efficiency and safety standards.

11 Proper __________ of welding tools extends their __________ and performance lifespan.

12 High __________ equipment ensures the structural integrity of welded structures.

13 The integration of IoT __________ allows for predictive __________ and minimizes

downtime.

14 Skilled operators are trained in handling __________ and troubleshooting issues.

15 As welding __________ evolves, so does the need for ongoing operator training.

Exercise 2: Grammar – Passive Voice Transformation

Transform the following sentences into passive voice.

1 The technician calibrates the welding machines regularly.

2 Operators use high-quality consumables for better welding results.

3 The company develops new welding technologies annually.

4 Programmable controls improve welding accuracy.

5 The safety protocols protect workers from hazards.

6 Engineers design advanced welding equipment with multiple features.

7 The training department conducts courses for new operators.

8 The maintenance team inspects the welding stations daily.

9 The manufacturer tests each welding unit before delivery.

10 The safety standards are updated by industry regulators regularly.

11 Skilled workers operate the welding robots.

12 The engineers optimize welding parameters for different materials.

13 The company installs new ventilation systems in welding areas.

14 The quality control team checks the welds for defects.

15 The company manufactures various types of welding equipment.

Exercise 3: Conditional Sentences (Type 1 and Type 2)

Complete the sentences with correct verb forms.

1 If the welding equipment __________ (be) properly maintained, it will last longer.

2 If the operator __________ (use) protective gear, accidents will be minimized.

3 If new welding technologies __________ (develop), production efficiency will improve.

4 If the company __________ (invest) in robotic welders, productivity would increase.

5 If the welding machines __________ (fail), the production line will stop.

6 If operators __________ (receive) adequate training, the quality of welds will rise.

7 If the equipment __________ (not be) calibrated regularly, weld quality could deteriorate.

8 If the industry __________ (adopt) IoT sensors, predictive maintenance would be possible.

9 If the company __________ (upgrade) its welding systems, safety risks would decrease.

10 If workers __________ (ignore) safety protocols, accidents are likely to happen.

11 If the manufacturer __________ (introduce) new features, it will attract more customers.

12 If the maintenance team __________ (perform) routine checks, equipment breakdowns would

be less frequent.

13 If the welders __________ (have) more experience, they could handle complex projects.

14 If the industry __________ (continue) to innovate, old equipment will become obsolete.

15 If the company __________ (prioritize) safety, fewer injuries would occur.

Exercise 4: Word Formation (Form nouns, adjectives, or adverbs)

Complete the sentences with the correct form.

1 The __________ (innovate) in welding equipment has revolutionized manufacturing.

2 Proper __________ (maintain) ensures the longevity of welding machines.

3 The engineer emphasized the importance of __________ (calibrate) for precise operations.

4 The new __________ (feature) increases safety and efficiency.

5 The __________ (durable) of welding joints depends on proper technique.

6 The company invests heavily in __________ (research) to develop better tools.

7 The welding process requires high __________ (concentrate) to ensure quality.

8 The technician performed __________ (accurate) tests to verify the machine's performance.

9 The __________ (automate) of welding processes reduces labor costs.

10 The operator's __________ (skill) greatly influences the weld quality.

11 The maintenance team is responsible for __________ (inspect) all equipment regularly.

12 The __________ (advance) in welding technology continues at a fast pace.

13 The new safety __________ (protocol) are mandatory for all operators.

14 The __________ (efficient) of the system reduces energy consumption.

15 The engineer designed a __________ (flexible) system adaptable to various welding tasks.

Answers:

1 innovation

2 maintenance

3 calibration

4 feature

5 durability

6 research

7 concentration

8 accurate

9 automation

10 skill

11 inspecting

12 advancement

13 protocols

14 efficiency

15 flexible

Exercise 5: Summarizing Main Ideas (Fill in the blanks)

Choose from: technology, safety, maintenance, innovation, efficiency, durability, features,

quality, automation, training, productivity, standards, equipment, development, efficiency

1 Modern welding __________ incorporate numerous advanced __________ to improve

performance.

2 Proper __________ is essential to prevent accidents and ensure worker health.

3 Regular __________ extends the lifespan of welding __________ and maintains optimal

operation.

4 Continuous __________ drives the evolution of new welding __________.

5 Improving __________ reduces waste and increases overall __________.

6 The __________ of welding joints depends on both equipment quality and operator skill.

7 The adoption of __________ welding systems boosts __________ in manufacturing processes.

8 Industry __________ regulate the minimum requirements for welding __________.

9 Skilled __________ programs are crucial for training operators to handle complex

__________.

10 The integration of IoT enhances __________ by enabling predictive __________.

11 Investing in high-quality __________ ensures consistent __________ and reduces rework.

12 The focus on __________ safety standards has increased awareness of potential hazards.

13 Technological __________ has led to faster welding speeds and better __________ control.

14 Continuous __________ in welding technology provides the competitive edge necessary for

modern industry.

15 Advances in __________ equipment facilitate the production of durable and high-quality

Unit 2

Equipment for Manual Arc Welding with Fusion

Manual arc welding with fusion, also known as shielded metal arc welding (SMAW), is a

fundamental method used in construction, manufacturing, and repair industries. This process

involves using an electric arc to melt and fuse metal pieces together, creating strong and durable

joints. The equipment required for this welding technique is specialized to ensure safety,

efficiency, and quality of the welding process. The core components of manual arc welding

equipment include a power source or welding machine, an electrode holder, welding electrodes,

a grounding clamp, and protective gear. The power source supplies the necessary electrical

energy to generate the arc, typically providing a variable voltage and current to adapt to different

welding conditions. Welding machines can be portable or stationary, depending on the

application. The electrode holder is a crucial part of the setup, as it securely holds the welding

electrode, which is a consumable rod coated with flux. The flux coating serves multiple

purposes: it stabilizes the arc, shields the molten metal from atmospheric contamination, and

adds alloying elements to improve weld quality. Electrodes come in various types and sizes,

selected based on the material thickness and welding position. Grounding clamps are attached to

the workpiece to complete the electrical circuit, ensuring a safe and stable welding process.

Protective gear, including welding helmets with dark lenses, gloves, aprons, and safety boots, is

essential to protect workers from intense heat, ultraviolet radiation, and sparks generated during

welding. In addition to basic equipment, modern welding setups might include accessories such

as wire feeders, automation controls, and cooling systems to enhance productivity and safety.

Proper maintenance of welding equipment is vital to prevent malfunctions and ensure consistent

weld quality. Safety standards and regulations govern the use of welding equipment,

emphasizing the importance of proper training and adherence to safety protocols. Skilled welders

must understand the characteristics of their equipment, including voltage settings, electrode

types, and safety procedures, to perform high-quality welds. Advances in welding technology

have led to the development of inverter-based power sources that are more energy-efficient and

portable. These modern systems often feature digital controls for precise adjustments, improving

overall welding performance. As industries evolve, so does the equipment, making continuous

education and training essential for welders.In conclusion, the equipment used in manual arc

welding with fusion is complex but vital for producing strong, high-quality welds. Proper

selection, operation, and maintenance of this equipment directly influence the safety of the

worker and the integrity of the welded structure.

Exercise 1: Fill in the blanks with the correct form of the word in brackets.

1 The (power) source provides the necessary energy for the welding process.

2 The (electrode) coating contains flux that protects the weld pool from oxidation.

3 Proper (ground) connection is essential for a safe welding operation.

4 The (equipment) must be regularly maintained to ensure optimal performance.

5 Welding (technique) varies based on the type of electrode used.

6 The (safety) gear includes helmets, gloves, and protective clothing.

7 Modern (welding) machines are often equipped with digital controls.

8 The (current) flow should be carefully adjusted to prevent defects.

9 The (operation) of welding equipment requires specialized training.

10 The (material) of the workpiece influences the choice of electrode.

11 The (application) of welding includes construction, repair, and manufacturing.

12 Proper (handling) of electrodes prevents accidents.

13 The (design) of portable welding machines allows for easy transportation.

14 (Maintenance) of equipment extends its service life.

15 The (regulation) standards ensure safety and quality in welding practices.

Exercise 2: Rewrite the sentences using the passive voice.

1 The technician operates the welding machine daily.

2 Welders clean and inspect the equipment regularly.

3 The manufacturer produces various types of electrodes.

4 Workers wear protective gear during welding.

5 The engineer designed the new welding system.

6 The safety regulations govern the use of welding equipment.

7 The electrician connects the power source to the circuit.

8 The company maintains the welding machines annually.

9 The operator adjusts the voltage according to the material.

10 The technician tests the equipment before use.

11 The workers repair the damaged cables.

12 The supervisor trains new welders on safety protocols.

13 The team installed the new inverter-based power source.

14 The inspector checks the quality of the welds.

15 The company supplies protective clothing to all workers.

Exercise 3: Correct the errors in the following sentences.

1 The welding equipment are essential for high-quality welds.

2 The electrode coating helps to protect the molten metal.

3 Modern welding machines has advanced features.

4 Safety gear are required during operation.

5 The operator must carefully adjust the current.

6 The company maintain their welding equipment regularly.

7 The power source provides the necessary voltage.

8 Welders must wear their protective gloves and helmet.

9 The technician checks the circuit connections before starting.

10 The quality of weld depends on the proper handling of equipment.

11 The safety regulations is strict in industrial welding.

12 The portable welding machines is easy to transport.

13 The flux coating are used to stabilize the arc.

14 Maintenance of the equipment is vital for safety.

15 The workers inspects the welds after completing the task.

Exercise 4: Write correct sentences using the words in brackets.

1 (the / welding / requires / proper / equipment)

2 (modern / systems / include / digital / controls)

3 (the / operator / adjusts / voltage / according to / material)

4 (safety / gear / is / essential / for / welders)

5 (the / maintenance / of / equipment / ensures / safety and efficiency)

6 (the / electrode / coated / with flux / improves / weld quality)

7 (the / power source / supplies / electrical / energy)

8 (welders / need / to / wear / protective / clothing)

9 (the / technician / tests / the / equipment / before / use)

10 (the / quality / of / welds / depends / on / proper technique)

11 (new / inverter-based / power sources / are / more / efficient)

12 (the / grounding / clamp / completes / circuit)

13 (the / safety / standards / regulate / welding practices)

14 (the / welding / process / involves / melting / metal)

15 (the / equipment / must / be / regularly / maintained)

Unit 3

Equipment for Welding in Carbon Dioxide and Argon Atmospheres

Welding in inert and semi-inert gases such as argon and carbon dioxide is a widely used

technique in modern metal fabrication, offering high-quality welds with minimal contamination.

The equipment used for welding in these gases is specially designed to create a controlled

environment around the weld pool, ensuring optimal results and safety. The primary component

of such systems is the power source or welding machine, which supplies the necessary electrical

current to generate an arc. These machines can be either constant voltage (CV) or constant

current (CC), depending on the welding process. In gas shielded welding, the machine is often

equipped with features to regulate the voltage and current precisely. A critical element in

welding with argon or carbon dioxide is the gas delivery system, which includes gas cylinders,

regulators, and hoses. The cylinders contain high-pressure inert or semi-inert gases, which are

fed into the welding torch through regulators that control the flow rate. Proper regulation of gas

flow is essential for maintaining a stable arc and preventing oxidation or contamination of the

weld. The welding torch, also called a welding gun, is designed to withstand high temperatures

and deliver the gas and electrode precisely. In gas tungsten arc welding (GTAW), or TIG

welding, the torch holds a non-consumable tungsten electrode, while in gas metal arc welding

(GMAW), or MIG welding, a consumable wire acts as the electrode. Protective shielding gas is

vital because it prevents atmospheric contamination, such as oxygen and moisture, from entering

the weld pool. Argon, being an inert gas, is commonly used in TIG welding for its stability and

ability to produce clean, precise welds on non-ferrous metals like aluminum and magnesium.

Carbon dioxide, on the other hand, is a semi-inert gas often used in MIG welding for its

affordability and deep penetration capabilities on steel. The safety of operators depends on

proper equipment maintenance and adherence to safety protocols. Gas cylinders must be stored

securely, and regulators checked regularly for leaks. Welding helmets, gloves, and protective

clothing are necessary to safeguard against sparks, ultraviolet radiation, and high temperatures.

Modern advancements have introduced automated and robotic welding systems that utilize these

equipment setups for high-volume production. Digital controls allow precise adjustments of

parameters, improving efficiency and weld quality. Additionally, modern gas delivery systems

are equipped with flow meters and sensors to monitor and optimize gas consumption. In

conclusion, equipment for welding in carbon dioxide and argon atmospheres is sophisticated and

vital for producing high-quality welds. Proper understanding and maintenance of this equipment

ensure safety, efficiency, and excellent weld integrity in various industrial applications.

Exercise 1: True or False?

Mark each statement as true or false. Correct the false statements.

1 The power source in gas shielded welding can be either constant voltage or constant current.

2 Gas cylinders used in welding contain low-pressure inert gases.

3 The welding torch in TIG welding holds a consumable wire as an electrode.

4 Proper regulation of gas flow is unnecessary for stable welding.

5 Argon is an inert gas often used for welding non-ferrous metals.

6 Carbon dioxide is an inert gas used mainly for welding aluminum.

7 Modern equipment includes digital controls to adjust welding parameters precisely.

8 Safety protocols in welding are optional if the equipment is well-maintained.

9 Gas regulators are checked regularly for leaks to ensure safety.

10 Welding helmets and gloves are not necessary when working with inert gases.

11 The use of inert gases in welding prevents oxidation of the weld.

12 MIG welding uses a non-consumable tungsten electrode.

13 The gas delivery system includes hoses, regulators, and cylinders.

14 Automated welding systems do not require operator supervision.

15 Oxygen is typically used as shielding gas in CO and argon welding.

₂

Exercise 2: Formulate questions based on these statements.

1 The equipment includes a power source and a gas delivery system.

2 Argon is used because it is an inert gas.

3 Gas regulators control the flow of gases from cylinders.

4 TIG welding uses a non-consumable tungsten electrode.

5 MIG welding uses a consumable wire as an electrode.

6 Proper maintenance of equipment is important for safety.

7 Modern systems have digital controls for parameter adjustment.

8 Gas cylinders must be stored securely.

9 The welding torch delivers both the gas and the electrode.

10 Carbon dioxide is a semi-inert gas used in MIG welding.

11 Safety equipment is optional if the equipment is new.

12 Shielding gases prevent atmospheric contamination.

13 Gas flow rate affects the stability of the arc.

14 Robotic welding systems are used in high-volume production.

15 Oxygen is usually used as shielding gas for steel welding.

Exercise 3: Correct the errors in the following sentences.

1 The power source in gas shielded welding can be either constant voltage or constant current.

2 Gas cylinders used in welding contain low-pressure inert gases.

3 The welding torch in TIG welding holds a consumable wire as an electrode.

4 Proper regulation of gas flow is unnecessary for stable welding.

5 Argon is an inert gas often used for welding non-ferrous metals.

6 Carbon dioxide is an inert gas used mainly for welding aluminum.

7 Modern equipment includes digital controls to adjust welding parameters precisely.

8 Safety protocols in welding are optional if the equipment is well-maintained.

9 Gas regulators are checked regularly for leaks to ensure safety.

10 Welding helmets and gloves are not necessary when working with inert gases.

11 The use of inert gases in welding prevents oxidation of the weld.

12 MIG welding uses a non-consumable tungsten electrode.

13 The gas delivery system includes hoses, regulators, and cylinders.

14 Automated welding systems do not require operator supervision.

15 Oxygen is typically used as shielding gas in CO and argon welding.

₂

Exercise 4: Fill in the blanks with correct prepositions.

1 The gas cylinders are stored ____ a secure location.

2 The welding machine is connected ____ the power supply.

3 Proper regulation of flow is essential ____ stable welding.

4 Argon is used ____ its inert properties.

5 The torch delivers gas ____ the electrode.

6 Gas flow rate affects the stability ____ the arc.

7 The regulator controls the flow ____ high-pressure cylinders.

8 Safety gear should be worn ____ all welding activities.

9 The gas is supplied ____ hoses from the cylinder to the torch.

10 The welding process is conducted ____ controlled environments.

11 The operator adjusts parameters ____ the digital control panel.

12 The gas prevents contamination ____ the weld pool.

13 Cylinders must be stored ____ upright position.

14 The system monitors gas consumption ____ sensors.

15 The protective shield is placed ____ the operator's face.

Exercise 5: Rewrite the sentences using the correct tense, especially complex and perfect

tenses.

1 The power source in gas shielded welding has been providing consistent current for years.

(Present perfect)

2 Modern welding systems are equipped with digital controls. (Present simple)

3 The operator adjusts the gas flow before starting the welding process. (Present simple)

4 Gas cylinders are stored safely when not in use. (Present simple)

5 The torch has been delivering gases and electrodes since the beginning of operation. (Present

perfect continuous)

6 The system had been checked for leaks before use. (Past perfect continuous)

7 The operator will have completed the setup by the time the welding begins. (Future perfect)

8 The equipment is being maintained regularly. (Present continuous passive)

9 The gases are supplied through hoses connected to high-pressure cylinders. (Present simple

passive)

10 The welding technique had been improved over many years. (Past perfect passive)

11 The safety protocols are being followed diligently by the workers. (Present continuous

passive)

12 The system will be monitoring the gas flow during operation. (Future continuous)

13 The operator had already adjusted the voltage when the problem occurred. (Past perfect)

14 The equipment has been used in many industrial applications. (Present perfect)

15 The gas regulators will have been checked by the technician by the end of the day. (Future

perfect passive)

Unit 4

Exercise 1: True or False

Decide whether each statement is true or false.

1 A welding transformer is used to convert AC voltage into a suitable form for welding.

2 Modern inverter welders provide a more stable arc than traditional transformers.

3 Gas welding cannot be performed without oxygen.

4 MIG/MAG welding uses a shielding gas such as argon or CO .

₂

5 Electrodes used in arc welding are only covered electrodes.

6 Welding cables must be insulated and properly connected.

7 Automatic welding is mainly used in manufacturing large steel structures.

8 Before welding, it’s essential to check grounding connections.

9 The wire feed mechanism in a welding machine is operated manually.

10 High-efficiency welding machines produce less heat and energy loss.

11 Welding equipment should not be used in damp or humid environments without protection.

12 TIG welding uses a tungsten electrode that does not get consumed during welding.

13 Oxygen is used in arc welding to increase the temperature of the arc.

14 Vacuum welding equipment is mainly used in aerospace and high-tech industries.

15 Modern welding machines do not require regular maintenance.

Exercise 2: Questions about the text

Answer these questions based on the previous exercise.

1 What is the purpose of a welding transformer?

2 Why are inverter welders considered more advanced?

3 Which gases are commonly used in MIG/MAG welding?

4 How do covered electrodes benefit manual arc welding?

5 Why must welding cables be insulated?

6 What types of welding are mainly automated?

7 What is the significance of checking grounding before welding?

8 How does the wire feed mechanism work?

9 Why are high-efficiency welders advantageous?

10 When should welding equipment not be used?

11 What is unique about TIG welding electrodes?

12 Why is oxygen not used in arc welding?

13 In which industries is vacuum welding mainly applied?

14 How often should modern welding equipment be maintained?

15 What safety precautions are important when working with damp conditions?

Exercise 3: Fill in the blanks with the correct tense (Present Perfect, Present Continuous,

Simple Present)

1 I __________ (use) welding equipment for over ten years.

2 Currently, the team __________ (perform) welding on the new structure.

3 We __________ (check) all cables before starting the job today.

4 He __________ (work) with inverter welders since last year.

5 Yesterday, they __________ (connect) the new welding transformer.

6 Welding machines __________ (be) serviced regularly to ensure safety.

7 I __________ (configure) the settings on the TIG welder right now.

8 My colleague __________ (test) the shielding gas flow for the last hour.

9 We __________ (discover) a fault in the grounding system recently.

10 This year, we __________ (conduct) many welding projects.

11 At the moment, the equipment __________ (operate) in automatic mode.

12 I __________ (not/use) the welding equipment for two weeks.

13 They __________ (install) new wire feeders last week.

14 He __________ (monitor) the weld quality throughout the process.

15 We __________ (finish) all the preparatory work before starting welding.

Exercise 4: Replace the nouns with the correct pronouns

1 The welding machine is very reliable. __________ works perfectly.

2 All the cables should be checked and secured. __________ must be in good condition.

3 The transformer supplies power to the welding torch. __________ is essential for stable

welding.

4 The operator tested the equipment yesterday. __________ was satisfied with the results.

5 The tools are kept in the toolbox. __________ are organized and clean.

6 The welding process requires proper shielding gas. __________ protects the weld pool.

7 The technician repaired the faulty cable. __________ replaced it with a new one.

8 The documentation covers all safety procedures. __________ must be followed.

9 The electrode is made of tungsten. __________ does not get consumed during TIG welding.

10 The supervisor checked the calibration of the welding equipment. __________ approved the

process.

11 The safety gear includes helmet, gloves, and apron. __________ is mandatory.

12 The team completed the welding tasks. __________ was efficient.

13 The instructions are clear. __________ help in setting up the equipment.

14 The welding fumes are hazardous. __________ should be ventilated properly.

15 The maintenance schedule is strict. __________ ensures the equipment's longevity.

Exercise 5: Fill in the correct prepositions

1 The welding machine is connected __________ the power supply.

2 The gas flows __________ the torch to protect the weld.

3 Before starting, check the settings __________ the manufacturer's instructions.

4 The cables run __________ the workshop floor to the power source.

5 The electrode is positioned __________ the workpiece during welding.

6 The shielding gas is supplied __________ the regulator.

7 The operator is responsible __________ maintaining safety standards.

8 Welding fumes should be ventilated __________ the welding area.

9 The control panel is located __________ the front of the machine.

10 The maintenance is scheduled __________ every six months.

11 The welding process takes place __________ a controlled environment.

12 The equipment is tested __________ a qualified technician.

13 The safety gear must be worn __________ all times.

14 The current flows __________ the electrode to the workpiece.

15 The cables are stored __________ a designated area after use.

Exercise 6: Vocabulary — fill in the blanks with words related to welding equipment

1 The __________ protects the welder from sparks and UV radiation.

2 An __________ welder supplies power and controls the welding process.

3 The __________ feeds wire into the weld pool automatically.

4 The __________ is made from tungsten and used in TIG welding.

5 The __________ is used to regulate the flow of shielding gas.

6 The __________ is used to clean and prepare the metal surface before welding.

7 The __________ is essential for safety and is worn as protective gear.

8 The __________ allows the operator to control the welding current precisely.

9 The __________ ensures the welding area is well-ventilated.

10 The __________ is a portable device used for small or repair welds.

11 The __________ is used to remove slag after welding.

12 The __________ is a device that cools down overheating equipment.

13 The __________ helps to prevent electrical shocks during welding.

14 The __________ is a protective shield that blocks harmful rays.

15 The __________ ensures the stability of the welding circuit.

Exercise 7: Translate into English (using welding vocabulary)

1 Вчера мастер проверял исправность сварочного трансформатора.

2 Сейчас команда настраивает сварочный аппарат.

3 Мы уже использовали инверторное оборудование в нескольких проектах.

4 В будущем планируем приобрести новую автоматическую сварочную систему.

5 Он всегда использует защитную маску и перчатки.

6 В течение месяца мы проверяли кабели и соединения.

7 В прошлом году оборудование проходило полное обслуживание.

8 Сегодня мы тестируем новую систему подачи проволоки.

9 Вечером я буду работать с газовой сваркой.

10 В последнее время мы изучаем новые виды сварочного оборудования.

11 Они уже завершили подготовительные работы по установке аппарата.

12 В будущем я собираюсь освоить сварку TIG.

13 Мы уже завершили сварочные работы на объекте.

14 В течение нескольких часов команда тестировала все параметры.

15 Сейчас я изучаю инструкции по эксплуатации современного сварочного оборудования.

Unit 5

Welding Processes

Welding is a fundamental manufacturing process that involves joining materials, typically metals

or thermoplastics, by causing coalescence. This technique has been utilized for centuries,

evolving significantly over time with technological advancements to meet the demanding needs

of modern industries such as aerospace, automotive, construction, and shipbuilding. The primary

principle of welding involves applying heat, pressure, or a combination of both to melt the base

materials, often adding a filler material to form a strong, permanent joint upon solidification.

Various welding processes have been developed, each suited to specific applications, material

types, and desired joint properties. Arc welding is one of the most common methods, utilizing an

electric arc to generate the necessary heat. This category includes processes like Shielded Metal

Arc Welding (SMAW), Gas Metal Arc Welding (GMAW or MIG), and Gas Tungsten Arc

Welding (GTAW or TIG). These techniques differ mainly in their power sources, electrode

types, and shielding methods. Resistance welding relies on passing current through the materials

to generate heat via electrical resistance. Techniques such as spot welding and seam welding fall

under this category and are widely used in sheet metal fabrication. Gas welding employs an oxy-

fuel flame to heat and melt the materials, often used for repairs and small-scale fabrication.

Despite being considered traditional, it remains relevant due to its portability and control. Laser

welding and electron beam welding are advanced processes that utilize highly focused energy

sources, providing precise control and high-quality joints, often in aerospace applications. Each

welding process has its advantages and disadvantages regarding speed, cost, quality, and

suitability for different materials. For example, TIG welding provides excellent precision but is

slower, whereas MIG welding offers high productivity but may have limitations with certain

materials. The quality of welded joints is critical for safety and performance. Consequently,

extensive testing, including visual inspection, ultrasonic testing, and X-ray inspection, is

performed to ensure structural integrity. Additionally, modern welding often incorporates

automation and robotics, enhancing consistency, safety, and efficiency. Despite its benefits,

welding presents challenges such as residual stresses, distortions, and the need for skilled

operators. Moreover, safety precautions are paramount due to the risks of burns, electric shock,

and exposure to harmful fumes. In conclusion, welding remains an indispensable process in

manufacturing, continually advancing through innovations to produce stronger, more precise,

and more sustainable joints that meet the increasingly complex demands of modern engineering.

Exercise 1. Conditional Sentences. Complete the sentences with the correct form of the

verb in parentheses.

1 If the welder (use) proper safety equipment, accidents (be) less likely.

2 If the materials (be) heated sufficiently, they (fuse) together effectively.

3 If the operator (not/maintain) the equipment regularly, it (break) down.

4 If the welding (be) done correctly, the joint (have) high strength.

5 If the technician (detect) flaws early, they (repair) them before testing.

6 If the company (invest) in automated welding systems, productivity (increase).

7 If the gas supply (fail), the welding process (stop) immediately.

8 If the materials (cool) too quickly, cracks (form) in the weld.

9 If the operator (train) well, the quality of the welds (improve).

10 If the welding parameters (be) set properly, the weld (be) defect-free.

11 If the design (be) complex, robotic welding (be) more suitable.

12 If the electrode (wear) out, it (need) replacement.

13 If the environment (be) too humid, welding (be) more challenging.

14 If the joint (not/prepare) properly, it (fail) under stress.

15 If the new techniques (adopt) widely, overall safety (be) enhanced.

Exercise 2. Past Perfect. Fill in the blanks with the correct form of the past perfect tense of

the verbs in parentheses.

1 By the time the inspection (begun), the welds (already/clean) and ready for testing.

2 The technician (realize) that he (forget) to adjust the welding current.

3 They (not/complete) the calibration before the production started.

4 The operator (have) to stop the process because the power supply (fail) unexpectedly.

5 After the materials (been) heated, they (been) joined successfully.

6 The team (test) the welds only after the equipment (be) properly maintained.

7 By the end of the shift, the workers (have) completed all the welds scheduled.

8 The welder (not/know) about the new safety standards until after the training.

9 The quality control inspector (find) that some welds (be) defective.

10 The engineer (decide) to replace the old electrode because it (wear) out.

11 The company (invest) in new robotic welders that (increase) efficiency.

12 The technicians (adjust) the parameters only after they (review) the previous results.

13 The supervisor (have) to halt the process because the gas flow (be) inconsistent.

14 The materials (already/ship) before the new safety protocols (be) introduced.

15 The welding process (improve) significantly after the team (implement) new techniques.

Exercise 3. Special Questions. Create a question for each statement.

1 The welding process requires high precision.

2 The technician inspected the welds after the production.

3 The company invested heavily in automation.

4 The electrodes wear out after extensive use.

5 The welds were tested using ultrasonic inspection.

6 The operator adjusts the welding parameters regularly.

7 The materials must be cleaned before welding.

8 The process can be automated for better consistency.

9 The results show that the joints are strong.

10 The safety standards are strictly followed.

11 The technician had to replace the power supply.

12 The weld was made using TIG welding.

13 The company plans to expand its welding operations.

14 The machine has been calibrated recently.

15 The quality depends on the skill of the operator.

Exercise 4. Match Definitions. Match each term to its correct definition.

Terms:

A. Arc welding

B. Resistance welding

C. Filler material

D. Welding joint

E. Welding defect

F. Welding helmet

G. Welding rod

H. Shielding gas

I. Welding parameters

J. Weld pool

K. Heat-affected zone

L. Welding electrode

M. Welding speed

N. Weld quality

O. Non-destructive testing

Definitions:

1 The area of metal that melts during welding.

2 A protective gas that shields the weld from contamination.

3 The process using an electric arc to join metals.

4 A defect such as cracks or porosity in a weld.

5 The equipment worn by welders to protect their eyes and face.

6 The material added to fill the joint during welding.

7 The base metals being joined.

8 The settings that control temperature, speed, and current during welding.

9 The zone of metal altered by heat but not melted.

10 The device that conducts current and produces the arc.

11 The speed at which welding is performed.

12 The quality and strength of a welded joint.

13 Techniques used to evaluate welds without damaging them.

14 The filler material used in gas tungsten arc welding.

15 The initial molten metal in the welding process.

Exercise 5. Sentence Construction. Using the words below, form meaningful sentences

related to welding processes.

1 Proper / safety / equipment / essential / for / welders.

2 Advanced / laser / welding / allows / precise / joints.

3 The / technician / regularly / calibrates / the / equipment.

4 Resistance / welding / is / commonly / used / in / automotive / manufacturing.

5 The / quality / of / welds / depends / on / operator / skill.

6 High / heat / is / generated / during / arc / welding.

7 Protective / gear / such / as / helmets / is / vital / in / welding.

8 The / filler / material / melts / to / join / metals / together.

9 Automated / welding / increases / efficiency / and / consistency.

10 The / weld / must / pass / inspection / to / ensure / safety.

11 Electrode / wear / requires / regular / replacement / in / arc / welding.

12 The / process / generates / fumes / that / must / be / ventilated.

13 Proper / joint / preparation / ensures / strong / weld /s.

14 The / heat / affected / zone / can / cause / distortions.

15 Skilled / operators / are / crucial / for / high-quality / welding.

Unit 6

Main Principles of Welding

Welding is a fabrication process that joins materials, usually metals or thermoplastics, by causing

coalescence. The main principles of welding involve the following key concepts:

Welding requires the application of heat to melt the base materials and, in some cases, additional

filler materials. The heat can be generated through various methods such as electric arc, gas

flame, laser, or friction.

The materials are heated to a temperature above their melting point, allowing them to fuse

together.

Upon

cooling,

they

form

a

strong,

permanent

joint.if

used):

In many welding processes, a filler material is added to strengthen the joint. This material melts

and joins the base metals together.

To ensure a strong weld, the parts to be joined must be properly aligned and held in position

during the welding process. This prevents defects such as cracks or weak points.

Welding often involves shielding the weld area from contamination by oxidizing gases,

moisture, or dirt. Shielding gases, fluxes, or coverings are used to protect the molten weld pool.

Solidification:

After welding, the joint cools and solidifies. Proper cooling rates are important to prevent

internal stresses, cracks, or distortions.

The final weld must meet specific standards for strength, durability, and appearance. Inspection

methods such as ultrasonic testing, X-ray, or visual examination are used to ensure quality.

Exercise 1: Fill in the blanks with the correct words from the list below:

Words: heat, melting, filler, protection, cooling, joint, materials, strength, impurities,

alignment

1.

Welding involves the application of __________ to the materials to join them together.

2.

The process requires the materials to reach a temperature where they begin to

__________.

3.

Sometimes, a __________ is added to enhance the strength of the weld.

4.

Proper __________ of the parts ensures a strong weld.

Answer:

5.

To prevent contamination, the weld area needs __________ from gases and dirt.

Answer:

6.

After welding, the materials need to undergo __________ to solidify properly.

Answer:

7.

The materials being joined are called the __________.

Answer: materials

8.

The main goal of welding is to create a weld with high __________ and durability.

9.

Removing __________ such as rust or oil from the surfaces before welding is essential.

Answer:

10. The weld joint must be properly designed to ensure the transfer of loads without failure.

Exercise 2: True or False? Correct the false statements.

1.

Welding does not require heat; it is done by cold joining methods.

Answer:

2.

The cooling process can sometimes cause internal stresses if not controlled properly.

3.

Shielding gases are used to protect the weld area from contamination.

Answer:

4.

The main purpose of welding is to cut materials apart.

Answer:

5.

Filler materials are only used in some welding processes, not all.

6.

Proper alignment of parts during welding is not very important.

7.

Welding joints are designed to withstand mechanical loads and stresses.

Answer

8.

Impurities like rust or oil must be cleaned before welding to ensure quality.

9.

The strength of a weld is not affected by the cooling rate after welding.

Answer

10. Welding can be performed without any protection from gases or environmental factors.

Exercise 3: Multiple Choice - Choose the correct answer for each question.

1.

What is the primary purpose of shielding gases in welding?

a) To cool the weld area

b) To protect the weld from oxidation and contamination

c) To add filler material

Answer

2.

Which of the following is NOT a common method of generating heat in welding?

a) Electric arc

b) Friction

c) Freezing

3.

Why is proper alignment important in welding?

a) To ensure the weld looks good

b) To prevent internal stresses and weak joints

c) To reduce the amount of filler material needed

Answer:

4.

What happens if impurities like rust or oil are not removed before welding?

a) The weld will be stronger

b) The weld may have defects and reduced strength

c) The welding process will be faster

Answer:

5.

Which element is added in some welding processes to improve weld quality?

a) Water

b) Filler metal

c) Oil

6.

What is the main reason for controlling the cooling rate after welding?

a) To prevent the weld from melting

b) To avoid internal stresses and cracking

c) To make the weld shiny

Answer

7.

Which of the following is a characteristic of a good weld?

a) Cracks and porosity

b) High strength and good appearance

c) Uneven surface

8.

Welding is a process of joining materials by:

a) Cutting and removing parts

b) Heating and fusing the materials together

c) Gluing with adhesives

Answer:

9.

Which of these is NOT an important principle of welding?

a) Proper heat application

b) Adequate cooling

c) Ignoring contamination

Answer:

10. The quality of a weld is typically checked by:

a) Visual inspection and testing methods

b) Guesswork

c) How fast it was done

Answer

Exercise 4: Match the term with its description.

Terms:

a) Heat, b) Filler, c) Cooling, d) Impurities, e) Alignment

Descriptions:

1.

The process of bringing parts into the correct position before welding.

2.

The process of reducing temperature after welding to ensure proper solidification.

Answer

3.

Substances like rust or oil that must be removed for quality welds.

Answer

4.

The energy used to melt the materials during welding

5.

Additional material added to the weld to improve strength

Exercise 5: Complete the sentences with the correct word from the list below:

Words: heat, weld, contamination, strength, joint, melting, electrode, shielding,

penetration, defect

Words

1.

The __________ is the area where two materials are joined together during welding.

Answer:

2.

Proper __________ protects the weld from atmospheric gases and impurities.

3.

To form a good weld, sufficient __________ must be applied to fuse the materials.

Answer

4.

An __________ conducts current and helps create the arc in electric arc welding.

5.

Excessive or insufficient __________ can cause weak welds or cracks.

Answer

6.

The process of __________ involves the material becoming liquid and fusing together.

Answer:

7.

If the weld has a __________, it can compromise the strength and durability of the joint.

Answer:

8.

The main purpose of welding is to create a strong and durable __________.

Answer:

9.

Adequate __________ ensures the weld penetrates deeply into the base materials.

Answer

10. Poor preparation can lead to __________ in the weld, reducing its overall quality.

Answer:

Exercise 6: True or False? Correct the false statements.

1.

The main principle of welding is to join materials without applying any heat.

2.

Proper cleaning of the surfaces before welding prevents impurities from weakening the

weld.

Answer:

3.

Welding always requires the use of filler material.

4.

Penetration in welding refers to how deep the heat affects the base materials.

Answer

5.

Contamination from dirt or oil can cause weld defects.

6.

Cooling the weld slowly can sometimes cause internal stresses and cracking.

Answer:

7.

The quality of a weld does not depend on the correct application of heat

8.

A good weld should have a uniform appearance and no visible defects.

Answer:

9.

Shielding gases are only used in gas welding and not in arc welding.

10. Welding processes are designed to join materials securely and reliably for structural or

aesthetic purposes.

Answer:

Unit 7

Alternative Welding Methods

Welding, as a critical process in manufacturing, construction, aerospace, and various engineering

sectors, traditionally relies on arc welding techniques such as Shielded Metal Arc Welding

(SMAW), Gas Metal Arc Welding (GMAW or MIG), and Tungsten Inert Gas (TIG) welding.

However, advancements in materials technology, environmental considerations, and the demand

for high-quality joints have driven the development and adoption of alternative welding methods.

These methods often offer unique advantages, such as the ability to join dissimilar materials,

weld in difficult positions, reduce thermal distortion, and improve weld integrity.

1. Friction Stir Welding (FSW)

Friction Stir Welding is a solid-state process developed in the early 1990s, primarily used for

aluminum alloys. It involves a specially shaped rotating tool that is plunged into the abutting

edges of two workpieces, generating heat through friction and plastic deformation. The material

softens without melting, allowing the tool to stir the materials together, creating a defect-free,

high-strength joint. FSW is renowned for producing minimal residual stresses and distortion,

making it ideal for aerospace, shipbuilding, and automotive applications. Its ability to weld

dissimilar metals, such as aluminum to steel, expands its utility.

2. Laser Beam Welding (LBW)

Laser Beam Welding utilizes a highly concentrated laser beam to deliver intense heat to the

materials, causing localized melting and fusion. This technique is characterized by high

precision, rapid welding speeds, and narrow heat-affected zones. It can be performed in various

positions and is suitable for thin sections, complex geometries, and high-volume manufacturing.

LBW is extensively used in microelectronics, medical device fabrication, and aerospace

industries, where accuracy and minimal thermal distortion are paramount.

3. Electron Beam Welding (EBW)

Electron Beam Welding employs a high-velocity beam of electrons generated in a vacuum

chamber. When the electrons impact the workpieces, their kinetic energy converts into heat,

causing localized melting and fusion. EBW produces deep, narrow welds with minimal

distortion and excellent mechanical properties. Due to its vacuum requirement, EBW is primarily

used for precision applications such as aerospace components, nuclear reactors, and military

hardware. Its ability to join dissimilar materials with high precision makes it indispensable in

advanced manufacturing.

4. Ultrasonic Welding

Ultrasonic Welding utilizes high-frequency vibrations, typically around 20 kHz, applied under

pressure to the materials to be joined. The vibrations induce intermolecular friction at the

interface, generating heat that causes the materials to fuse without melting. This method is

especially suitable for plastics and thin metallic foils. It is widely used in the electronics industry

for joining wire to terminals, medical device assembly, and packaging, owing to its speed,

cleanliness, and suitability for automation.

5. Diffusion Welding

Diffusion Welding is a solid-state process where two surfaces are pressed together at elevated

temperatures over extended periods. The process relies on atomic diffusion across the interface,

resulting in a metallurgical bond without melting. It produces joints with high strength and

excellent integrity, often used in aerospace, nuclear, and precision instrumentation. The process

requires strict control of temperature, pressure, and cleanliness and is valued for producing high-

quality, defect-free joints.

6. Explosion Welding (Explosive Bonding)

Explosion Welding, also known as explosive bonding, involves the use of controlled explosive

energy to accelerate one metal plate into another at high velocity. The impact causes a

metallurgical bond characterized by a distinctive wave-like interface. This method is particularly

effective for joining dissimilar metals, such as copper to steel, where traditional welding

techniques fail due to differences in melting points or thermal expansion. Explosion welding is

used in large-scale applications like ship hulls, pipelines, and heat exchangers.

Advantages of Alternative Welding Techniques:

Ability to join dissimilar materials with different melting points or thermal expansion properties.

Reduced heat input, minimizing thermal distortion and residual stresses.

Suitability for welding delicate, thin, or complex geometries.

Capability to perform welding in inaccessible or difficult positions.

Improved weld quality, mechanical properties, and corrosion resistance in some cases.

Challenges and Limitations:

High initial investment for specialized equipment.

Requirement for skilled operators and precise process control.

Limitations in material compatibility for certain methods.

Complexity in process optimization and quality assurance.

Limited availability of industry standards compared to traditional methods.

Conclusion

As industries strive for higher quality, efficiency, and sustainability, alternative welding methods

continue to evolve, offering solutions that traditional techniques cannot provide. Their ability to

join advanced materials, reduce thermal effects, and enable innovative designs makes them

invaluable in modern manufacturing. Continuous research and technological advancements will

likely expand their applications and accessibility.

15 Questions Based on the Text

1 What is the primary difference between traditional arc welding and alternative welding

methods?

2 Which welding process is mainly used for aluminum alloys and involves a rotating tool?

3 How does Laser Beam Welding achieve high precision in joining materials?

4 Why is Electron Beam Welding performed in a vacuum environment?

5 Name a common application of Ultrasonic Welding.

6 What is the basic principle behind Diffusion Welding?

7 How does Explosion Welding create a metallurgical bond between metals?

8 Why is Friction Stir Welding considered advantageous for aerospace applications?

9 What are some benefits of using alternative welding methods over traditional ones?

10 What are some common challenges faced when implementing alternative welding

techniques?

11 For which materials is Ultrasonic Welding especially suitable?

12 What distinguishes Electron Beam Welding from other welding processes?

13 In which industries is Explosion Welding most commonly used?

14 How does the heat input in diffusion welding compare to traditional arc welding?

15 Why might industries prefer laser welding for microelectronics manufacturing?

True/False Exercises

Exercise 1:

a) Friction Stir Welding involves melting the materials before joining.

b) Electron Beam Welding is performed in a vacuum chamber to prevent electron scattering

Exercise 2:

a) Ultrasonic Welding is mainly used for welding thick steel plates.

b) Explosion Welding uses controlled explosives to join metals without melting them.

Matching Definitions

Term Definition

1. Friction Stir Welding

A. Uses high-frequency vibrations to connect plastics and thin

metals.

2. Laser Beam Welding

B. Utilizes a concentrated laser beam for precise, high-speed

welding.

3. Electron Beam Welding

C. Employs a high-velocity electron beam in a vacuum for deep

welds.

4. Ultrasonic Welding

D. Generates heat through friction from a rotating tool to join

metals.

5. Diffusion Welding E. Joins materials by atomic diffusion at elevated temperature and

pressure.

6. Explosion Welding F. Uses explosive energy to cause high-velocity impact and

bonding.

Unit 8

Traditional Types of Welding

Welding is a fundamental process in the manufacturing and construction industries, used to join

materials, primarily metals and thermoplastics, through various techniques that cause the

materials to fuse together. Traditional welding methods have been developed over centuries and

remain essential in many applications despite the advent of modern, automated processes. Each

type of welding has specific advantages, limitations, and suitable applications, depending on the

materials involved, the desired strength of the joint, and environmental conditions. One of the

earliest and most widely used forms of welding is arc welding, which involves creating an

electric arc between an electrode and the base material to generate heat. This heat melts the

metals, allowing them to fuse upon cooling. Arc welding includes several subtypes such as

Shielded Metal Arc Welding (SMAW), also known as stick welding, which uses a consumable

electrode coated with flux to protect the weld area from contamination. SMAW is appreciated

for its portability and versatility, making it suitable for outdoor and fieldwork. Another popular

type is Gas Metal Arc Welding (GMAW), commonly called MIG welding, which uses a

continuous wire feed and shielding gas to produce cleaner and more precise welds. Gas Tungsten

Arc Welding (GTAW), or TIG welding, employs a non-consumable tungsten electrode and inert

gas shielding. TIG welding allows for high-quality welds with excellent control, especially on

thin materials, but requires more skill and is generally slower. Submerged Arc Welding (SAW)

involves forming the weld under a layer of flux, providing deep penetration and high

productivity, primarily used in large-scale manufacturing. Each of these welding types has

different equipment, safety considerations, and typical applications. Besides arc welding,

oxygen-acetylene welding, also called oxy-fuel welding, is a traditional process that uses a flame

produced by burning a mixture of oxygen and acetylene gases. It is often used for welding,

cutting, and heating metals, especially in repair work and artistic applications. Oxy-fuel welding

is valued for its portability and ability to work on various metal thicknesses, but it is less

efficient for high-volume production compared to arc welding methods. Traditional welding

techniques require skilled operators to ensure high-quality joints and safe working conditions.

Proper safety measures, including protective gear and ventilation, are essential to prevent injuries

and health hazards like inhalation of harmful fumes. Despite the development of newer welding

technologies, traditional methods remain vital due to their simplicity, cost-effectiveness, and

adaptability to various environments. In conclusion, understanding the different types of

traditional welding is crucial for selecting the appropriate method for specific tasks. Whether it is

stick welding for construction, TIG for delicate work, or oxy-fuel for repair jobs, each technique

plays a vital role in metal fabrication. Mastery of these methods requires technical knowledge,

practical skills, and adherence to safety standards. As technology advances, traditional welding

continues to evolve, integrating new materials and processes to meet the demands of modern

industry.

Exercise 1. Vocabulary Matching. Match the terms with their correct definitions.

a) SMAW

b) GMAW

c) GTAW

d) SAW

e) Oxy-fuel welding

f) Flux

g) Electrode

h) Shielding gas

i) Deep penetration

j) Non-consumable electrode

definitions

1 A type of arc welding using a coated electrode.

2 Welding that uses a continuous wire and shielding gas.

3 Tungsten electrode with inert gas shielding.

4 Welding under a flux layer for high productivity.

5 Welding using a flame produced by burning gases.

6 Material that protects the weld pool from contamination.

7 The part of the electrode that melts to form the weld.

8 Gas that surrounds the weld to prevent oxidation.

9 The ability of weld to fuse deeply into the base material.

10 An electrode that does not melt during welding.

Exercise 2. Fill in the blanks with the correct welding methods

1 ____ is often used for repair work and artistic metalwork because of its portability.

2 ____ welding is known for producing high-quality welds with excellent control.

3 In ____ welding, a flux layer is used to cover the weld and protect it from contamination.

4 ____ is the most common method for large-scale manufacturing due to its high productivity.

5 ____ welding uses a consumable wire electrode fed continuously to the weld pool.

6 ____ welding employs a non-consumable tungsten electrode and inert gas shielding.

7 ____ involves melting metals with a flame produced by burning gases like oxygen and

acetylene.

8 ____ welding can be performed on various metals, including steel, aluminum, and copper.

9 Safety gear and proper ventilation are essential when performing ____ welding to prevent

health hazards.

10 Traditional welding techniques remain vital because of their ____ and adaptability.

Exercise 3. Convert the sentences to plural form

1 The welding process requires a skilled operator.

2 An electrode is used in arc welding.

3 The flux protects the weld from contamination.

4 The safety measure includes protective gear.

5 The welding technique is suitable for thin metals.

6 The equipment needs regular maintenance.

7 The welder uses a torch to perform the job.

8 The process produces harmful fumes.

9 The operator adjusts the welding current.

10 The weld needs inspection after cooling.

Exercise 4. Complete the sentences with appropriate numbers

1 The process can be performed on ____ different types of metals.

2 The welder used ____ electrodes during the project.

3 The flux layer is ____ millimeters thick.

4 The machine operates at ____ amperes.

5 The welding took ____ hours to complete.

6 The company produces ____ welds per day.

7 The technician adjusted the gas flow for ____ seconds.

8 The welding temperature reached ____ degrees Celsius.

9 The weld joint was ____ centimeters long.

10 The technician performed ____ inspections before approving the weld.

Exercise 5. Translate the following sentences into English

1 Традиционные методы сварки используются на строительных площадках.

2 Сварочные работы требуют высокой точности и опыта.

3 Основные виды сварки включают дуговую, газовую и кислородно-ацетиленовую.

4 Сварочные аппараты могут быть портативными или стационарными.

5 Важно соблюдать правила безопасности при выполнении сварочных работ.

6 Охрана труда и вентиляция необходимы для предотвращения вредных воздействий.

7 Технологии сварки постоянно улучшаются и развиваются.

8 Некоторые виды сварки требуют высокой квалификации оператора.

9 Сварочные швы должны проходить проверки на качество и прочность.

10 Традиционные методы остаются актуальными благодаря своей простоте и надежности.

Unit 9

New Welding Methods

Welding technology has seen significant advancements in recent years, leading to more efficient,

precise, and safer methods. Traditional welding techniques like arc welding and MIG welding

are still widely used, but new methods are emerging to meet modern industry demands. One such

technique is laser welding, which uses a focused laser beam to join metals with high precision

and minimal heat distortion. Laser welding is particularly useful in industries such as aerospace

and automotive manufacturing, where accuracy is critical. Another innovative method is friction

stir welding, which involves stirring two pieces of metal together using a rotating tool. This

method produces strong, high-quality joints without melting the materials, making it energy-

efficient and environmentally friendly. Additionally, hybrid welding combines different

techniques, such as laser and arc welding, to optimize speed and quality. Advancements in

automation and robotics have also transformed welding processes. Modern robotic welders can

work continuously with high precision, reducing human error and increasing safety. The

development of new welding materials, such as specialized alloys and consumables, further

enhances the durability and performance of welded joints. These new welding methods are

shaping the future of manufacturing by enabling complex designs, reducing production time, and

improving safety standards. As technology continues to evolve, the industry is expected to see

even more innovative solutions that will redefine how metals are joined together.

Упражнение 1. Вставьте правильную форму глагола в скобках

1 New welding techniques __________ (revolutionize) the manufacturing industry.

2 Researchers __________ (develop) laser welding for over a decade.

3 The robotic systems __________ (perform) precise welds consistently.

4 Scientists __________ (explore) new materials for better welds.

5 The industry __________ (adopt) friction stir welding more widely in recent years.

6 Companies __________ (invest) heavily in automation.

7 Innovative methods __________ (reduce) the environmental impact of welding.

8 Manufacturers __________ (try) hybrid welding to improve efficiency.

9 The technology __________ (allow) for joining thinner metals without distortion.

10 Engineers __________ (design) new equipment for high-speed welding.

11 The industry __________ (see) a shift toward more sustainable practices.

12 Welding processes __________ (become) faster and safer due to technological progress.

13 New materials __________ (enable) stronger and more durable joints.

14 They __________ (test) the latest welding machines in the laboratory.

15 The future of welding __________ (look) promising with ongoing innovations.

Упражнение 2. Создайте предложения, используя данные слова

1 (laser, welding, precise, metals)

2 (robotic, systems, increase, safety)

3 (hybrid, methods, combine, advantages)

4 (materials, new, improve, joint strength)

5 (industry, adopt, innovative, techniques)

6 (automation, speed, productivity, enhance)

7 (environment, friendly, welding, methods)

8 (manufacturers, develop, faster, equipment)

9 (technologies, transform, how, we weld)

10 (researchers, explore, high-performance, alloys)

11 (precision, essential, aerospace, welding)

12 (companies, invest, in, advanced)

13 (welding, quality, increase, significantly)

14 (industry, face, new, challenges)

15 (future, of, welding, looks, bright)

Упражнение 3. Переведите предложения на английский, используя лексические

конструкции

1 Новые методы сварки позволяют создавать более прочные соединения.

2 Исследователи разрабатывают лазерную сварку с высокой точностью.

3 Роботизированные системы обеспечивают постоянное качество.

4 Использование новых материалов делает сварные швы более долговечными.

5 В промышленности все чаще применяют гибридные методы сварки.

6 Технологические инновации значительно сокращают время производства.

7 Новые методы сварки уменьшают негативное воздействие на окружающую среду.

8 Компании инвестируют в развитие автоматизированных систем.

9 Современные технологии позволяют сваривать тонкие металлы без деформации.

10 Исследовательские центры тестируют новые сварочные аппараты.

11 В будущем появятся еще более эффективные методы соединения металлов.

12 Внедрение новых технологий повышает безопасность работников.

13 Компании расширяют свои исследования в области новых сплавов.

14 Образование и обучение специалистов становятся важными.

15 Перспективы развития сварочной индустрии очень многообещающие.

Упражнение 4. Сделайте вопросительные предложения по образцу

Образец:

They / develop / new welding techniques? → Do they develop new welding techniques?

1 Researchers / explore / innovative materials?

2 Companies / invest / in automation?

3 The industry / adopt / hybrid welding methods?

4 Engineers / design / faster equipment?

5 Scientists / test / new welding processes?

6 Technicians / work / with robotic systems?

7 Manufacturers / improve / existing welding methods?

8 The research center / conduct / experiments?

9 They / implement / environmentally friendly techniques?

10 Experts / study / the effects of new materials?

11 The industry / see / a shift towards automation?

12 They / develop / high-speed welding tools?

13 Companies / train / workers in new methods?

14 Innovators / create / more sustainable welding solutions?

15 The industry / face / new challenges?

Does the industry face new challenges?

Unit 10

The Welding Arc and Its Properties

The welding arc is a fundamental component of many welding processes, playing a crucial role

in the creation of strong, durable joints between metals. It is an electric discharge that occurs

when an electric current passes through a gap between two conductive materials, typically

electrodes and the workpiece. The arc generates intense heat, often exceeding 6,500 degrees

Celsius, which melts the base metals and allows them to fuse together. This process is used in

various welding techniques, including arc welding, TIG welding, and MIG welding. One of the

most significant properties of the welding arc is its high temperature, which enables the melting

of metals with relatively low energy input compared to other welding methods. Additionally, the

arc produces bright light and ultraviolet radiation, which require proper protective gear for

welders to avoid injury. The stability of the arc is another important property, as a stable arc

results in cleaner welds and fewer defects. Factors such as voltage, current, and electrode type

influence the stability and characteristics of the arc. The arc's shape and size can be controlled by

adjusting the welding parameters, impacting the quality of the weld. The arc also produces a

gaseous environment around the weld zone, often called shielding gas, which protects the molten

metal from oxidation and contamination. Variations in the arc length can affect the heat input

and weld bead profile, so precise control is essential for high-quality welds. The properties of the

welding arc are influenced by the type of electrode used, the polarity, and the welding technique.

Understanding the physical and chemical properties of the welding arc helps in optimizing

welding processes, improving weld quality, and ensuring safety. Advances in welding

technology continue to enhance the control of arc properties, leading to more efficient and

environmentally friendly welding methods. Proper training and knowledge of arc properties are

essential for welders to perform their work effectively and safely.

Exercise 1. Vocabulary Match

Match the following words with their correct definitions.

1 Arc

2 Electrode

3 Melting

4 Shielding gas

5 Stability

6 Contamination

7 Fuses

8 Intense

9 Parameters

10 Oxidation

11 Discharge

12 Fused

13 Conductive

14 Polarity

15 Weld

Exercise 2. Fill in the Blanks. Complete the sentences with the correct form of the verbs in

brackets.

1 The welding arc (produce) high temperatures.

2 Welders (use) protective gear to stay safe.

3 The stability of the arc (depend) on the settings.

4 Different electrodes (have) various properties.

5 The arc (generate) intense light.

6 Proper shielding gas (prevent) contamination.

7 The process (require) precise control of parameters.

8 Metal (melt) when the temperature is high enough.

9 The characteristics of the arc (influence) the quality of the weld.

10 The electrode (conduct) electricity from the power source.

11 The welding process (involve) high heat and electricity.

12 The arc (be) essential for arc welding techniques.

13 The properties of the arc (determine) the efficiency of the process.

14 Welding (help) join metals permanently.

15 Safety measures (be) critical in welding.

Exercise 3. Transform the Sentences into Passive Voice

Rewrite the following sentences in passive voice.

1 The welder controls the arc length carefully.

2 The process produces high temperatures.

3 The operator adjusts the welding parameters.

4 The shielding gas protects the molten metal.

5 The technician observes the stability of the arc.

6 The high heat melts the metals quickly.

7 The technician monitors the welding process.

8 The electrode conducts electricity to the workpiece.

9 The process creates a strong joint.

10 The welder maintains safety precautions.

11 The technician inspects the weld after finishing.

12 The operator sets the voltage and current.

13 The process involves melting and solidifying metals.

14 The arc emits bright light.

15 The protective gear shields the welder from radiation.

Exercise 4. Multiple Choice (Vocabulary Focus)

Choose the correct answer for each question.

1 The high temperature of the welding arc is necessary to:

a) Cool the metals quickly

b) Melt the base metals

c) Prevent oxidation

d) Reduce welding speed

2 Which gas is commonly used as shielding gas?

a) Oxygen

b) Carbon dioxide

c) Argon

d) Nitrogen

3 The stability of the arc affects:

a) The color of the weld

b) The strength of the electrical current

c) The quality of the weld

d) The type of electrode

4 Which property describes an electric discharge?

a) Conductive

b) Discharge

c) Melting

d) Fusing

5 The process of joining metals by melting is called:

a) Cutting

b) Welding

c) Soldering

d) Bending

6 Which of the following influences the heat input during welding?

a) The color of the electrode

b) The arc length

c) The ambient temperature

d) The type of protective gear

7 Oxidation in metals results in:

a) Rust formation

b) Increased strength

c) Improved conductivity

d) Better welds

8 The term "parameters" in welding refers to:

a) The physical size of the welder

b) The settings like voltage and current

c) The type of metal being used

d) The brand of equipment

9 Which property is essential for conducting electricity?

a) Insulation

b) Conductivity

c) Transparency

d) Resistance

10 The arc produces:

a) Only heat

b) Light and heat

c) Only ultraviolet radiation

d) No emission

11 Proper safety gear protects welders from:

a) Noise

b) Ultraviolet and infrared radiation

c) Falling objects

d) Electrical shocks only

12 The melting point of metals is a critical factor in:

a) Selecting the electrode type

b) Controlling the arc length

c) Determining the welding speed

d) All of the above

13 Fusing metals involves:

a) Cooling metals rapidly

b) Melting and joining them together

c) Cutting through metals

d) Applying pressure only

14 An unstable arc can lead to:

a) Stronger welds

b) Defects and poor quality

c) Faster welding speed

d) Lower temperatures

15 Which element is commonly used in electrodes for arc welding?

a) Plastic

b) Steel

c) Copper

d) Aluminum

Exercise 5. Sentence Correction

Identify and correct the grammatical errors in the following sentences.

1 The welding arc are very hot.

2 The technician observe the stability of the arc.

3 Welding process is involve high temperatures.

4 The electrodes conducts electricity efficiently.

5 The high heat melts the metals quickly.

6 Proper shielding gases helps prevent contamination.

7 The parameters of welding is important.

8 The arc emits bright light which can damage eyes.

9 The process involve melting and solidification of metals.

10 The welder controls the arc carefully.

11 The properties of the arc influence the quality of welds.

12 Safety measures is essential in welding.

13 The high temperature can cause burn injuries.

14 The shielding gases prevents oxidation.

15 The welding process have many benefits.

Exercise 6. Essay Completion

Complete the following paragraph with appropriate words from the list: temperature, control,

arc, stability, properties, safety, melting, gas

The welding (1) is an essential part of many manufacturing processes. The (2) of the arc

determines the quality of the weld. High (3) is necessary to melt the metals effectively. To

ensure a consistent arc, (4) of parameters such as voltage and current is vital. The (5) around the

weld zone, often called shielding (6), protects the molten metal from contamination. Proper (7)

procedures are crucial to prevent accidents and injuries. Understanding the physical and

chemical (8) of the welding arc helps in optimizing the process and achieving strong, durable

joints.

Exercise 7. Short Answer Questions

Answer the following questions briefly.

1 What is the main purpose of the welding arc?

2 Why is shielding gas important in welding?

3 How does the arc's stability affect the weld?

4 Name one common shielding gas used in welding.

5 What safety precautions should welders take?

6 How does the temperature of the arc influence the welding process?

7 What property of the arc produces ultraviolet radiation?

8 Why is it necessary to control the arc length?

9 What happens if contamination occurs during welding?

10 How do different electrodes affect the welding process?

11 Why is understanding the properties of the welding arc beneficial?

12 What safety equipment is typically worn by welders?

13 How does the welding arc generate heat?

14 What is meant by the term "parameters" in welding?

15 How can technological advances improve welding techniques?