How Can Mastering Welding Terminology Enhance Your Craft?

Embark on a journey through the intricate and precise world of welding, where each term and technique is a critical thread in the fabric of this skilled trade. Whether you're a veteran welder, a newcomer starting your first project, or an enthusiast eager to understand the craft, mastering the language of welding is essential. The specialized vocabulary used in this field is not just a collection of words but the foundation of quality, safety, and efficiency in every weld you create.

This detailed glossary of welding terms is your ultimate companion, crafted to guide you through the labyrinth of industry-specific lingo. It spans from the workshop slang that resonates among craftsmen to the intricate technical terms that define the exact nature of materials and processes. Our goal is to illuminate the welding terminology, transforming complex jargon into clear concepts that enhance your understanding and execution of welding tasks.

As we delve into this glossary, you'll discover familiar terms and encounter new ones, each a vital component of the welding lexicon. Together, they form the dialect spoken in the heat of the workshop and the quiet planning of a project blueprint. Whether your aim is to refine your existing welding vocabulary, seek clarity on certain terms, or construct your knowledge base from scratch, this guide is your beacon. Let's spark our curiosity and venture into the rich language of welding terms and definitions, ensuring that you're well-equipped to tackle any welding challenge with confidence and expertise.

A – C

In the world of welding, every term has its place, and understanding them is key to the craft. Let's expand our glossary with more essential welding terms from A to C, ensuring a more complete reference.

A

ACETONE: A highly flammable liquid used to stabilize acetylene in its cylinder by dissolving it under pressure.

ACETYLENE: A highly combustible gas that, when mixed with oxygen, creates a flame hot enough to weld and cut metals.

ACTUAL THROAT: Also known as the throat of a fillet weld, it's the shortest distance from the weld root to the face of the weld, crucial for assessing weld strength.

AIR-ACETYLENE: A flame made by burning acetylene with air, not as hot as an oxy-acetylene flame but still used for welding.

AIR-ARC CUTTING: A process where an electric arc melts metal, and a blast of air removes it, cutting the metal.

ALLOY: A blend of two or more elements, with at least one being a metal, which has metallic properties.

ALTERNATING CURRENT (AC): An electric current that reverses direction periodically, used in certain welding applications.

AMMETER: A device that measures the flow of electrical current in a circuit.

ANNEALING: A heat treatment process that softens metal, making it easier to work with.

ARC BLOW: The deflection of an electric arc caused by magnetic forces, which can affect welding quality.

ARC BRAZING: A brazing process where an electric arc provides the heat.

ARC CUTTING: Cutting metals by melting them with an electric arc.

ARC LENGTH: The distance between the electrode tip and the molten pool of metal during welding.

ARC-OXYGEN CUTTING: A cutting process that uses an arc and oxygen to cut metals.

ARC VOLTAGE: The voltage across the welding arc.

ARC WELDING: A family of welding processes that melt metals using an electric arc.

AS WELDED: The condition of a weld as it is completed, before any finishing or treatment.

ATOMIC HYDROGEN WELDING: A welding method using an arc between two metal electrodes in a hydrogen atmosphere.

AUSTENITE: A phase in steel, non-magnetic and able to dissolve carbon, formed at high temperatures.

AXIS OF A WELD: A line running through the length of a weld, at the center of its cross-section.

B

BACK FIRE: A brief flashback of the flame into a torch, often with a popping sound, which can lead to a sustained backfire if not corrected.

BACK PASS: A weld layer over the root pass to ensure complete penetration and smoothness.

BACK UP: Support for the backside of a joint during welding, preventing burn-through and ensuring a solid back bead.

BACK WELD: A weld made on the reverse side of a joint.

BACKHAND WELDING: A technique where the flame points towards the finished weld.

BACKING STRIP: Material placed at the root of a weld to support molten metal.

BACKING WELD: A bead applied at the joint root for complete penetration.

BACKSTEP: A welding technique where successive beads are laid in the opposite direction to the main welding progression.

BARE ELECTRODE: An uncoated welding electrode.

BARE METAL-ARC WELDING: An arc welding process using a bare or lightly coated electrode without applied pressure.

BASE METAL: The metal that is being welded or cut.

BEAD WELD: A weld made of one or more beads on an uninterrupted surface.

BEVEL ANGLE: The angle formed between the prepared edge of a piece of metal and a plane perpendicular to its surface.

BLACKSMITH WELDING: Also known as forge welding, it's a traditional technique of joining metals by heating and hammering.

BLOCK BRAZING: A brazing process using heated blocks to join metals with a nonferrous filler metal.

BLOW HOLE: A defect in a weld, appearing as a void or bubble caused by trapped gas.

BOND: The junction where the weld metal and base metal meet.

BOXING: Extending a fillet weld around a corner of a joint.

BRAZING: A welding process using a nonferrous filler metal with a melting point above 800 ºF (427 ºC) that is distributed by capillary action.

BRAZE WELDING: Similar to brazing, but the filler metal is not distributed by capillary action.

BRIDGING: A defect where a gap at the root of the weld is spanned by weld metal.

BUCKLING: Distortion caused by the heat of welding.

BUILDUP SEQUENCE: The order in which weld beads are deposited in a multipass weld.

BUTT JOINT: A joint where the edges of two pieces of metal are placed together and welded.

BUTT WELD: A weld in a butt joint.

BUTTER WELD: A bead laid on an unbroken surface to achieve desired properties or dimensions.

C

CAPILLARY ATTRACTION: The force that causes liquid filler metal to flow into the joint to be brazed, not by gravity, but by surface tension.

CARBIDE PRECIPITATION: A phenomenon in stainless steel where carbon combines with chromium, reducing corrosion resistance.

CARBON-ARC CUTTING: A cutting process using the heat of a carbon arc.

CARBON-ARC WELDING: A welding process using an arc between a carbon electrode and the work.

CARBURIZING FLAME: An oxyacetylene flame with excess acetylene, which can add carbon to the metal.

CASCADE SEQUENCE: A welding technique where subsequent beads are staggered for a cascading effect.

CASE HARDENING: A process of hardening the surface of metal by diffusing elements into it, followed by heat treatment.

CHAIN INTERMITTENT FILLET WELDS: Two lines of intermittent fillet welds in a T or lap joint, staggered for strength.

CHAMFERING: Preparing the edge of a joint member for welding, not including square groove welds.

COALESCENCE: The fusing of metals when heated during welding.

COATED ELECTRODE: An electrode with an external flux coating to stabilize the arc and improve weld quality.

COMMUTATOR CONTROLLED WELDING: A spot or projection welding process controlled by an electrical device.

COMPOSITE ELECTRODE: A filler metal electrode made of more than one metal, used in arc welding.

COMPOSITE JOINT: A joint formed by both thermal and mechanical processes.

CONCAVITY: The inward curvature of a weld bead.

CONCURRENT HEATING: Applying supplemental heat during welding to prevent distortion.

CONE: The part of a gas flame closest to the torch tip.

CONSUMABLE INSERT: Filler metal placed in the root of a joint before welding.

CONVEXITY: The outward curvature of a weld bead.

CORNER JOINT: A joint between two pieces at a right angle.

COVER GLASS: Clear glass used to protect the eyes from spatter during welding.

COVERED ELECTRODE: An electrode with a flux coating to improve the weld and stabilize the arc.

CRACK: A fracture in the weld with a sharp tip and high length-to-width ratio.

CRATER: A depression at the end of a weld bead.

CRITICAL TEMPERATURE: The temperature at which a metal changes its crystal structure.

CURRENT DENSITY: The amount of electric current per unit area of the electrode.

CUTTING TIP: A specialized torch tip for cutting metal.

CUTTING TORCH: A torch used for cutting metal with oxygen and fuel gases.

CYLINDER: A container for storing compressed gases used in welding.

By including these terms, we've enriched our glossary to provide a more thorough understanding of welding terminology. Whether you're a beginner or a seasoned welder, knowing these terms will help you communicate effectively and work safely in the welding industry.

D – F

D

Defect: A welding defect is a flaw that makes a weld unacceptable under specific standards. Defects include cracks, gas pockets, and areas where the weld hasn't properly fused with the base metal.

Deposited Metal: The metal that's added to a joint during welding. Once it cools, it becomes a permanent part of the weld.

Deposition Efficiency: The ratio of the weight of the metal actually used in the weld to the total weight of metal consumed during the process. Higher efficiency means less waste.

Depth of Fusion: The distance that welding heat penetrates into the base metal. Proper depth is necessary for a strong weld.

Die: A tool used in welding to shape metal or to hold parts together while they're being welded.

Die Welding: A type of forge welding where metal is heated in a furnace and then shaped and fused using dies.

Dip Brazing: A brazing process where parts are dipped into a molten bath, and a filler metal is used to join them through capillary action.

Direct Current Electrode Negative (DCEN): An arrangement in arc welding where the electrode is negative and the workpiece is positive, affecting the heat distribution.

Direct Current Electrode Positive (DCEP): The opposite of DCEN, with the electrode being positive and the workpiece negative.

Discontinuity: An interruption in the normal structure of a weld, which may or may not be a defect.

Drag: In cutting, the distance between where the cutting torch enters the metal and where it exits.

Ductility: The ability of metal to stretch without breaking. High ductility is important for metals that need to bend or move without cracking.

Duty Cycle: The amount of time a welding machine can operate at a given output without overheating, usually expressed as a percentage over a 10-minute period.

E

Edge Joint: A joint made by welding the edges of two pieces of metal together, often used with sheet metal.

Edge Preparation: The process of shaping the edges of metal before welding to ensure a strong joint.

Effective Length of Weld: The part of the weld that contributes to holding the pieces together.

Electric Arc: A discharge of electricity across a gap that generates intense heat for welding.

Electrode: A piece of metal that conducts electricity to the weld area and can be consumable or non-consumable.

Electrode Force: The pressure applied by electrodes in resistance welding to ensure a good weld.

Electrode Holder: A tool that holds the electrode and conducts current during welding.

Electrode Skid: The sliding movement of an electrode over the work surface in certain welding processes.

Embossment: A raised area on the metal surface.

Etching: A method to prepare metal for examination by revealing its structure.

F

Face Reinforcement: Extra weld metal on the surface of the joint, which may need to be removed if excessive.

Face of Weld: The visible surface of the weld where welding was performed.

Faying Surface: The surface of the metal that will be joined to another piece by welding.

Ferrite: A form of iron with a specific crystal structure, important in steel's properties.

Filler Metal: Metal added during welding to fill the joint.

Fillet Weld: A triangular weld used to join two surfaces at right angles.

Filter Glass: Colored glass used in welding helmets to protect the eyes from harmful rays.

Flame Cutting: A process of cutting metal using a flame.

Flame Gouging: Removing metal using a flame, similar to cutting.

Flame Hardening: Using a flame to harden the surface of steel.

Flame Softening: Using a flame to soften steel.

Flash: Excess metal and oxide expelled during resistance welding.

Flash Welding: A resistance welding process where heat and pressure are applied to join metal.

Flashback: A dangerous condition where the flame burns back into the welding equipment.

Flat Position: A welding position where the weld is laid from above and the weld face is horizontal.

Film Brazing: A brazing process using molten filler metal poured over the joint.

Flowmeter: A device that regulates the flow of gases in welding.

Flow Welding: A process where molten filler metal is poured over the surfaces to be joined.

Flux: A substance used to clean and prepare metal surfaces for welding.

Forehand Welding: A welding technique where the flame is directed ahead of the weld.

Forge Welding: A process where metal is heated and then joined by hammering or pressing.

Free Bend Test: A test to check the flexibility and soundness of a weld.

Full Fillet Weld: A fillet weld where the size is equal to the thickness of the thinner piece being joined.

Furnace Brazing: A brazing process where parts are heated in a furnace and joined using a filler metal.

Fusion: The melting and mixing of base metal and filler metal during welding.

Fusion Zone (Filler Penetration): The area of base metal that has melted in the weld.

By expanding and clarifying the definitions in this section, we ensure that anyone, from beginners to experts, can understand the essential welding terms from D to F. This knowledge is vital for quality workmanship and effective communication in the field of welding.

G – I

G

Gas Carbon-Arc Welding: A welding method using an arc between a carbon electrode and the workpiece, often without filler metal.

Gas Metal-Arc Welding (GMAW): Known as MIG welding, this uses an electric arc and a wire electrode to join metals together.

Gas Pocket: A trapped bubble of gas in the weld, which can cause weak spots.

Gas Tungsten-Arc Welding (GTAW): Also called TIG welding, it uses an arc between a tungsten electrode and the workpiece with an inert gas shield.

Gas Welding: A process using a gas flame to melt and join metals.

Globular Transfer: A way of transferring molten metal in large droplets across the arc in welding.

Goggles: Protective eyewear with colored lenses to shield eyes from harmful light during welding.

Groove: A channel prepared in the metal to receive weld metal.

Groove Angle: The total angle formed by the edges of the metal to be welded.

Groove Face: The surface of the metal within the groove.

Groove Radius: The curve inside a J or U-shaped groove.

Groove Weld: A weld filling a groove between two metals to join them.

Ground Connection: The attachment of the welding circuit to the metal being welded.

GTAW: Another term for Gas Tungsten-Arc Welding or TIG welding.

Guided Bend Test: A test where a metal sample is bent to check its strength and flexibility.

H

Hammer Welding: An old-fashioned method of joining metals by hammering.

Hand Shield: A protective device for the face and eyes, held by hand during welding.

Hard Facing: A technique where a tough material is welded onto a surface to make it resistant to wear.

Hard Surfacing: Similar to hard facing, it's applying a hard material to a softer metal surface.

Hardening: A process to increase metal hardness by heating and then quickly cooling it.

Heat Affected Zone: The part of the metal that changes structurally due to welding heat.

Heat Time: The length of time heat is applied during pulse welding.

Heat Treatment: Heating and cooling metal to change its properties for better performance.

Heating Gate: An opening in a mold for preheating parts before welding.

Helmet: A head-worn protective device with a filter glass for welding.

Hold Time: The duration electrodes are pressed together after welding current stops.

Horizontal Weld: A weld made on a vertical surface with a horizontal direction.

Horn: Part of a spot welding machine that holds the electrode.

Horn Spacing: The distance between the horns or platens in a welding machine.

Hot Short: A state when metal loses strength before melting.

Hydrogen Brazing: Brazing in a hydrogen atmosphere.

Hydromatic Welding: A type of welding with controlled pressure.

Hygroscopic: Tending to absorb moisture easily.

I

Impact Test: A test to measure how well a material can absorb energy without breaking.

Impregnated-Tape Metal-Arc Welding: A welding process using a tape with flux around the electrode.

Induction Brazing: A method using electrically induced heat to join metals with a filler.

Induction Welding: Fusion using heat from electrical resistance in the workpiece.

Inert Gas: A gas that doesn't react with the metal or filler during welding.

Interpass Temperature: The temperature of weld metal before the next layer is added.

J – M

J

Joint: The area where two pieces of metal or other materials come together to be welded. There are various joint types, such as butt, corner, edge, lap, and tee, each serving a specific purpose in welding.

Joint Penetration: The depth a weld reaches into the joint, not including any weld reinforcement. This is important for determining the strength of the weld.

K

Kerf: The gap or space left after metal has been cut away. The width of the kerf affects how materials fit together and the quality of the weld.

L

Lap Joint: A joint where two pieces overlap and are welded at the edges. It's often used when joining sheets of different thicknesses.

Layer: A single pass of weld material. In complex welds, multiple layers are used to fill a joint or build up a surface.

Leg of a Fillet Weld: The distance from the base of the joint to the top of the weld. It helps describe the size of a fillet weld.

Liquidus: The lowest temperature at which a metal or alloy is completely liquid.

Local Preheating: Heating a specific area before welding to make the process easier or to prevent cracking.

Local Stress Relieving: Reducing stress in a specific area of the weld by heating and then cooling it.

M

Manifold: A device that connects several gas cylinders to one gas line, ensuring a steady flow for welding.

Martensite: A very hard structure formed in steel when it's cooled quickly. It's important for making steel stronger and harder.

Mash Seam Welding: A type of welding where metal sheets are joined by pressing and heating along the seam.

Melting Point: The temperature at which a metal starts to melt.

Melting Range: The temperature span between when a metal starts to melt and when it's fully liquid.

Melting Rate: How fast the welding electrode melts, by weight or length, over time.

Metal-Arc Cutting: Cutting metal by melting it with an electric arc.

Metal-Arc Welding: An arc welding process using a metal electrode to fuse the electrode and the workpiece together.

Metallizing: A method of applying a metallic layer to a surface, often used to repair parts.

MIG (Metal-Inert-Gas) Welding: A welding process where a wire electrode is continuously fed from a spool, used mainly for welding aluminum and steel.

Mixing Chamber: The part of a welding torch where gases mix before burning.

Multi-Impulse Welding: Making welds with more than one burst of electricity.

Multipass Welds: Welds made with several layers, often used for thicker materials.

By expanding on the original content and including additional terms from the reference list, this edited section provides a more comprehensive overview of welding terms from J to M. The definitions are kept concise and straightforward for easy understanding.

N - P

N

Neutral Flame: A balanced oxyacetylene flame with equal oxygen and acetylene, ideal for welding various metals without changing their properties.

Nick Break Test: A test where a notched weld is broken to check for internal flaws like slag or poor fusion.

Nonferrous: Metals like aluminum, copper, and brass that don't have iron. They need special welding techniques due to their unique properties.

Normalizing: Heating steel above a certain temperature and then cooling it in air to relieve internal stresses.

Nugget: The small, solid area formed in the metal during resistance welding.

O

OFW (Oxyfuel Welding): A process using a flame from oxygen and a fuel gas, like acetylene, for welding, cutting, or brazing.

Open Circuit Voltage (OCV): The voltage between a welding torch and the workpiece when no welding current is flowing.

Overhead Position: A difficult welding position where the weld is done from underneath the joint.

Overlap: When weld metal sticks out past the weld's edge.

Oxidizing Flame: An oxyacetylene flame with too much oxygen, which can oxidize the metal.

Oxyacetylene Cutting: Cutting metal by maintaining a temperature with an oxyacetylene flame.

Oxyacetylene Welding: A welding process using an oxyacetylene flame.

Oxy-Arc Cutting: Cutting metal with an arc and oxygen.

Oxy-City Gas Cutting: Cutting metal with a flame from city gas and oxygen.

Oxygen Cutting: A process for cutting metals using oxygen's chemical reaction with the metal at high temperatures.

Oxygen Gouging: Using oxygen to cut a groove in metal.

Oxy-Hydrogen Cutting: Cutting metal with a flame from hydrogen and oxygen.

Oxy-Hydrogen Welding: Welding with a flame from hydrogen and oxygen.

Oxy-Natural Gas Cutting: Cutting metal with a flame from natural gas and oxygen.

Oxy-Propane Cutting: Cutting metal with a flame from propane and oxygen.

P

Pass: A single layer of weld along a joint. Thick materials may need several passes.

Peening: Hammering the weld to relieve stress and shape the weld bead as it cools.

Penetrant Inspection: A test that uses a liquid to find surface cracks or defects in materials.

Percussive Welding: A resistance welding process where electrical energy and pressure are applied together.

Perlite: A mixture of ferrite and iron carbide in steel, formed at a specific cooling point.

Pitch: The space between welds, measured from the center of one weld to the next.

Plug Weld: A weld made in a hole to join two pieces of metal.

Poke Welding: A spot welding process where one electrode is pressed manually.

Porosity: Gas pockets or voids in a weld.

Positions of Welding: The four main welding positions: flat, horizontal, overhead, and vertical.

Postheating: Applying heat to a welded area after welding.

Postweld Interval: The time between welding and the start of cooling in resistance welding.

Preheating: Heating metal before welding or cutting.

Pressure Controlled Welding: Making multiple spot or projection welds with a pressure sequencing device.

Pressure Welding: Any welding process that uses pressure to complete the weld.

Preweld Interval: The time before welding when material is preheated.

Procedure Qualification: Showing that welds made by a specific process meet set standards.

Projection Welding: A resistance welding process that makes welds at certain points or projections.

Pulsation Welding: A spot, projection, or seam welding process with interrupted current.

Push Welding: A welding technique where the welding gun is pushed forward for better control.

Q – S

Q

Quenching: A process where heated metal is cooled quickly by plunging it into water, oil, or air to harden it.

R

Reaction Stress: Stress that remains in a structure due to the heat of welding, which can cause warping if not managed.

Reducing Flame (Carburizing Flame): A flame with more fuel than oxygen, used in welding to add carbon to the metal.

Regulator: A device that controls gas pressure from a cylinder to the torch for a stable flame.

Reinforced Weld: Extra weld metal added to the joint, creating a stronger bond.

Residual Stress: Stress that stays in a material after it has been thermally or mechanically treated.

Resistance Brazing: A brazing process using electric current to bond metals with a filler that melts at high temperatures.

Resistance Butt Welding: A welding process where parts are joined across their entire contact area using electrical resistance.

Resistance Spot Welding (RSW): A method using electric current to weld metal without needing a filler rod.

Resistance Welding: Welding processes that use electrical resistance and pressure to join metals.

Reverse Polarity: A direct current arc welding setup with the workpiece as the negative and the electrode as the positive.

Rockwell Hardness Test: A test measuring the hardness of materials by the depth of penetration of a penetrator under fixed conditions.

Root and Related Terms: The closest point of contact in a joint to be welded, with various related terms defining specific aspects of this area, such as root crack, root edge, root face, root of joint, root of weld, root opening, and root penetration.

S

Scarf: The chamfered or beveled edge of a joint.

Scarfing: The process of removing surface defects or preparing metal surfaces using a special torch.

Seal Weld: A weld that ensures tightness to prevent leaks, commonly used in pipes and containers.

Seam Welding: The process of welding a continuous seam in sheet metal.

Selective Block Sequence: A welding sequence chosen to create a specific stress pattern in the welded material.

Series Welding: A resistance welding process where multiple welds are made at once with a single transformer.

Sheet Separation: The gap around a weld in spot, seam, and projection welding.

Shielded Welding: An arc welding process protected from the atmosphere by flux, electrode covering, or inert gas.

Shoulder (Root Face): The part of the edge that is not beveled or grooved in a joint.

Shrinkage Stress (Residual Stress): Stress that remains after a material has been cooled or treated.

Single Impulse Welding: A welding process using a single burst of current to create a weld.

Size of Weld: The dimensions of a weld, important for determining the strength of the joint.

Skip Sequence (Wandering Sequence): A welding technique where welding is performed in non-continuous, or 'skipping' segments.

Slag Inclusion: Non-metallic material trapped in the weld or between the weld and base metal.

Slot Weld: A weld made in an elongated hole to join two pieces of metal.

Slugging: The improper practice of adding separate material to a joint before welding.

SMAW (Shielded Metal Arc Welding): A welding process using a consumable electrode coated with flux.

Soldering: A process that joins metals by melting a filler metal at temperatures below 450 ºC.

Solidus: The highest temperature at which a metal or alloy is completely solid.

Spacer Strip: A strip used to maintain the separation at the root of a joint during welding.

Spall: Chips or fragments that can come off electrodes during welding.

Spatter: Metal particles expelled during welding that do not become part of the weld.

Spot Welding: A process where metal pieces are joined using heat from electrical resistance.

Spray Transfer: A method where molten metal is transferred across an arc in small droplets.

Spray Welding: Also known as spray arc welding or GMAW, a welding process using a spray of molten metal.

Staggered Intermittent Fillet Weld: A welding pattern where weld segments are alternated for stability.

Stored Energy Welding: A welding method using accumulated electrical energy.

Straight Polarity: A direct current arc welding setup with the workpiece as the positive and the electrode as the negative.

Stress Relieving: Heating metal to reduce internal stresses caused by various manufacturing processes.

String Bead Welding: A technique for welding thick pieces with layers of beads.

Stud Welding: A process that joins a metal stud to another workpiece using an arc and pressure.

Submerged Arc Welding: An arc welding process using a blanket of granular material to shield the weld.

Surfacing: Adding filler metal to a surface to improve its properties or dimensions.

T - Z

T

Tack Weld: A temporary weld that holds parts together before final welding. It's crucial for alignment and preventing distortion.

Tee Joint: A joint where two metal pieces meet at right angles, resembling the letter 'T'. It's often used in frameworks.

Temper Colors: Colors that appear on steel when heated, indicating different temperatures for processes like tempering.

Temper Time: The period during resistance welding when current flows for tempering or heat treatment after welding.

Tempering: Heating hardened steel below a critical temperature to reduce stress, increase ductility, and adjust toughness.

Tensile Strength: The maximum stress a material can withstand while being stretched before breaking.

Tension Test: A test to determine a material's elastic properties and tensile strength by pulling it apart until it breaks.

Thermit Crucible: A container where a thermit reaction, producing molten metal for welding, occurs.

Thermit Mixture: A blend of metal oxide and aluminum used in thermit welding to create molten metal and slag.

Thermit Mold: A mold that shapes the parts to be welded in thermit welding.

Thermit Reaction: A reaction between metal oxide and aluminum that generates superheated molten metal and slag.

Thermit Welding: A welding process using the heat from a thermit reaction to fuse metal, sometimes with added pressure.

Throat Depth: The distance from the center of welding electrodes or platens to the closest obstruction in resistance welding.

Throat of Fillet Weld: The measurement from the joint root to the fillet weld's face, indicating weld strength.

TIG Welding: Also known as GTAW, it uses a non-consumable tungsten electrode for a clean welding process.

Toe Crack: A crack at the edge of a weld, in the base metal.

Toe of the Weld: The point where the weld face meets the base metal.

Torch: A tool for gas welding or cutting, controlling the flame and heat.

Torch Brazing: A brazing process using a gas flame and a filler metal that melts above 800 ºF but below the base metal's melting point.

Transverse Seam Welding: Seam welding at a right angle to the seam welding machine's throat depth.

Tungsten Electrode: A non-filler metal electrode used in arc welding, made mostly of tungsten.

U

Underbead Crack: A hidden crack below the weld bead, within the heat-affected zone.

Undercut: A groove in the base metal next to the weld that weakens the joint if left unfilled.

Undercutting: A crater at the weld edge caused by incorrect welding technique or speed.

Upset: A localized increase in metal volume at a weld due to pressure.

Upset Welding: A resistance welding process where heat from electric current and pressure fuse the entire contact area.

Upsetting Force: The pressure applied during flash or upset welding.

V

Vertical Position: Welding with the weld axis vertical, requiring skill to manage the molten pool affected by gravity.

W

Wandering Block Sequence: A welding technique that alternates welding blocks to control distortion and minimize warping.

Wandering Sequence: A welding method where welds are not continuous but staggered to distribute heat and reduce warping.

Wax Pattern: A wax replica used in investment casting to create a mold for molten metal.

Weave Bead: A weld bead created with a side-to-side oscillation to increase width and control slag.

Weaving: An oscillating technique in welding to spread the weld deposit and aid in slag formation.

Weld: The fusion of metals by heating, with or without pressure and filler metal.

Weld Bead: The result of a single welding pass.

Weld Gauge: A tool for checking weld size and shape.

Weld Metal: The portion of a weld that was molten during welding.

Weld Symbol: A symbol indicating the type of weld desired.

Weldability: A material's ability to be welded into a strong bond.

Welder Certification: A written confirmation that a welder's work meets set standards.

Welder Performance Qualification: A test of a welder's ability to create welds that meet specific criteria.

Welding Leads: Cables that connect the welding current source to the electrode holder and workpiece.

Welding Positions: The four positions for welding: flat, horizontal, overhead, and vertical.

Welding Pressure: The force applied to the parts being welded during the process.

Welding Procedure: The detailed methods used in creating a weldment.

Welding Rod: The filler metal used in gas welding, brazing, and certain arc welding processes.

Welding Technique: The specific details of a welding operation controlled by the welder or operator.

Welding Tip: The end of a gas torch designed for welding.

Welding Torch: A tool for controlling gas flow in welding and brazing.

Welding Transformer: A device that provides the desired welding current.

Weldment: An assembly made by welding parts together.

Wire Feed Speed: The rate at which filler metal is fed into an arc welding or thermal spraying process.

Work Lead: The cable connecting the welding current source to the workpiece.

X

X-Ray: A method to inspect the internal structure of a weld for defects using radiographic testing.

Y

Yield Point: The stress level at which a material begins to deform permanently and won't return to its original shape after the load is removed.

By understanding these terms, anyone in the welding field, from novices to experts, can communicate effectively and ensure high-quality welding practices.

Mastering the Welder's Lexicon: A Conclusion

The journey through the intricate landscape of welding terminology culminates here, but the learning never ceases. Each term we've dissected serves as a crucial pillar in the vast structure of welding knowledge. For practitioners in the field, from the green apprentice to the seasoned artisan, these terms are more than mere words—they are the tools for crafting excellence, ensuring safety, and achieving precision in every bead and joint.

Keep this comprehensive glossary within arm's reach as you navigate the ever-changing tides of welding technologies and methodologies. It's an indispensable resource as you encounter novel materials, innovative techniques, and unforeseen challenges. The welding industry is dynamic, continuously shaped by advancements and discoveries. Your ability to adapt and grow, powered by a robust understanding of welding terms, is your ticket to thriving in this competitive arena.

Whether you're laying the foundation of your welding career or building upon years of experience, knowledge is your unwavering ally. Let this glossary be your guide, a constant companion on your path to welding mastery. Each term you internalize not only enriches your professional vocabulary but also sharpens your skills, setting you on course for a fulfilling and prosperous journey in the world of welding.