WELDER / CUTTER
Because of its strength, welding is used to construct and repair ships, automobiles, spacecraft and thousands of other manufactured products. Welding is used to join beams when constructing buildings, bridges and other structures, and pipes in pipelines, nuclear power plants and refineries.
Welders use all types of welding equipment in a variety of positions, such as flat, vertical, horizontal and overhead. They may perform manual welding, in which the work is entirely controlled by the welder, or semi-automatic welding, in which the welder uses machinery, such as a wire feeder, to help perform welding tasks. They generally plan work from drawings or specifications, or by analyzing damaged metal parts, using their knowledge of welding and metals. They select and set up welding equipment and examine welds to insure they meet standards or specifications. Some welders have more limited duties. They perform routine production work that has already been planned and laid out. These jobs do not require knowledge of all welding techniques.
Cutters dismantle large objects, such as ships, railroad cars, automobiles or aircraft. Some operate and monitor cutting machines similar to those used by welding machine operators.
In some production processes—in which the work is repetitive and the items to be welded are relatively uniform—automated welding is used. In this process, a machine performs the welding tasks while monitored by a welding machine operator. Welding machine operators set up and operate welding machines as specified by layouts, work orders, or blueprints. Operators must constantly monitor the machine to ensure that it produces the desired weld.
Welders and cutters are often exposed to potential hazards. They wear protective clothing, safety shoes, goggles, hoods with protective lenses, and other devices to prevent burns and eye injuries, and to protect them from falling objects.
Automated welding machine operators are not exposed to as many hazards. A face shield or goggles generally provide adequate protection. Because some metals may give off toxic gases and fumes as they melt, Federal regulations require ventilation to meet strict guidelines to minimize these hazards. Occasionally, some workers are in contact with rust, grease and dirt on metal surfaces.
Some welders are isolated for short intervals while they work in booths constructed to contain sparks and glare. Welders often work in a variety of awkward positions, having to make welds while bending, stooping, or working overhead. In some settings, however, working conditions are much better and there are few hazards or discomforts. Overtime is sometimes necessary to complete special projects.
Welders and cutters need good eyesight, good hand-eye coordination and manual dexterity. They should be able to concentrate on detailed work for long periods and be able to bend, stoop, and work in awkward positions. In addition, welders need to be adaptable, as it is becoming increasingly common for welders and cutters to receive cross-training for other production jobs.
Training for welders can range from a few weeks of school or on-the-job training for low skilled positions to several years of combined school and on-the-job training for highly skilled jobs. Formal training is available in high schools, vocational schools and post-secondary institutions such as vocational-technical institutes, community colleges and private welding schools. The Armed Forces operate welding schools as well.
Some employers provide training to help welders improve their skills. Courses in blueprint reading, shop mathematics, mechanical drawing, physics, chemistry and metallurgy are helpful. A knowledge of computers is gaining importance, especially for welding machine operators, as some welders are becoming responsible for the programming of computer-controlled welding machines, including robots.
Some welders become certified, a process whereby the employer sends a worker to an institution, such as an independent testing lab or technical school, to weld a test specimen to specific codes and standards required by the employer. The testing procedures are based on the standards and codes set by one of several industry associations with which the employer may be affiliated. If the welding inspector at the examining institution determines that the worker has performed according to the employer's guidelines, he or she then certifies that the welder being tested is able to work with a particular welding procedure.
Welders can advance to more skilled welding jobs with additional training and experience. They may be promoted to welding technicians, supervisors, inspectors or instructors. Some experienced welders open their own repair shops.
Median earnings for welders and cutters were about $478 a week in 1996. The middle 50 percent earned between $346 and $605. The top 10 percent earned more than $807, and the lowest 10 percent earned less than $278.
More than one-fourth of welders belong to unions. Among these are the International Association of Machinists and Aerospace Workers; the International Brotherhood of Boilermakers, Iron Ship Builders, Blacksmiths, Forgers and Helpers; the International Union, United Automobile, Aerospace and Agricultural Implement Workers of America; the United Association of Journeymen and Apprentices of the Plumbing and Pipe Fitting Industry of the United States and Canada; and the United Electrical, Radio, and Machine Workers of America.
Welders, cutters, and welding machine operators held about 453,000 jobs in 1996. About 9 out of 10 welders and cutters were employed in manufacturing, services, construction or wholesale trade. The majority of those in manufacturing were employed in transportation equipment, industrial machinery and equipment, or fabricated metal products. All welding machine operators were employed in manufacturing industries, primarily fabricated metal products, machinery and motor vehicles. Almost 2 of 5 welders are employed in six States: Texas, California, Ohio, Pennsylvania, Michigan and Illinois—States heavily dominated by automobile and fabricated metal products manufacturing, and by the petroleum and chemical industry.
Opportunities for those who wish to become welders, cutters, and welding machine operators differ by occupational specialty. Employment of welders and cutters is expected to increase slowly, while that of welding machine operators should remain unchanged through the year 2006. Most job openings will result from the need to replace experienced workers who transfer to other occupations or leave the labor force. Certified welders, especially those certified in more than one process, will have much better employment opportunities than non-certified welders.
As research in welding technology expands, an increase in the use of automated and robotic welding techniques in manufacturing will result in the employment of welding machine operators staying about level, despite an expected increase in production. Manual welders, however, especially those with a wide variety of skills, will increasingly be needed for sophisticated fabrication tasks and repair work that do not lend themselves to automation. Also, the aging of the Nation's infrastructure is adding to the number of metal products needing repairs and will provide additional opportunities. Welders can expect to find more jobs in the business services industry as companies increasingly contract out repair and maintenance functions. Welders, cutters, and welding machine operators in construction and manufacturing are vulnerable to periodic layoffs due to economic downturns.