Materials and Joins

• Eye, hand, foot protection
• Guards and clamping
• Consequences of ignoring PPE

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Workshop safety and PPE

• Magnetic vs non-magnetic
• Ductile vs malleable
• Properties affect join choice

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Metals & Properties

• Ductile = bends/draws
• Malleable = hammered to shape
• Hard/Tough resist wear/impact

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Key Terms: Ductile, Malleable, Hardness, Toughness

• Mechanical: bolts, rivets
• Fusion: welds by melting
• Choose by load and access

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Joint Families: Mechanical vs Fusion

• Wire + shielding gas
• Short, consistent stick-out
• Fit-up and tacks first

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MIG Essentials

• Stick flux makes shielding
• Less wind-sensitive than MIG
• For MIG use shields/indoors

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Stick (Arc) vs MIG Outdoors

• Clean to bright metal
• Set parameters, fit-up, clamp
• Tack before full weld

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Prep & Clamping Workflow

• Zinc fumes risk
• Coating causes porosity
• Grind off zinc, extract fumes

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Galvanised Steel Hazards

Name the defect
• First corrective action
• Cleanliness first

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Defects & First Fixes

• Base metal changed by heat
• Properties shift near weld
• Manage with correct heat

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​Heat-Affected Zone (HAZ)

• Mark and centre-punch
• HSS bit and clamp the stack
• Use washer as needed

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Drill & Rivet / Bolt Workflow