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As an example of the importance in learning proper welding skills, I offer
the following true story regarding overwelding.

It is a common problem that
often results when welders believe that if a little weld is good, then a bigger weld
is probably better.

Overwelding is so common that it has its own term—“gorilla
welding.” Gorilla welds often are referred to as strong and ugly. I once subscribed
to this myth. It is easy to argue that they are ugly, but are they really strong?
When I attended Hiwassee College in Madisonville, Tennessee, in the
1960s, I worked as a welder in a local shop that specialized in farm equipment
repair welding.

Like many young welders, I thought I was the world’s best
welder. My welds never cracked. I even convinced the shop owner to offer this
warranty on my welds: “If our welds crack, we fix them for free.”
To ensure that my welds did not fail, I made the biggest gorilla welds you
have ever seen.

Everyone knew that if I welded it, my welds would not fail.
Although my welds never cracked, the base metal alongside my weld often did.
Cracks beside my welds meant my warrantee did not apply, so I could bill
the farmer for my new welds.

Although I stayed busy rewelding parts with
cracks alongside my welds, my customers were happy with my work because
they also thought a bigger weld was better.
By the time a local farmer got rid of his dump trailer that I had kept “fixing”
for him, there was a 3-inch wide series of welds on the hinge point.

Today, I
realize that my welded repairs failed because of the size of the welds.
Often I made large welds on thin sheet metal parts that were subjected to
vibration as the equipment was used in the fields.

Each time a crack appeared
next to one of my previous welds, I would just add another weld. Not all overwelding today is as blatant as mine was, but it still is a problem.
In addition to being costly, overwelding can produce a welded joint that
cannot withstand the designed forces or vibration.

Overwelded joints are not as
flexible, and the resulting joint stresses are focused alongside the weld, which is
why cracks always appeared just alongside my welds.

Accompanying the text is a carefully prepared supplements package, which
includes an Instructor’s Guide, an Instructor Resources CD, and a Workbook.
The Instructor’s Guide contains chapter objectives, answers to the end of
chapter review questions and answers to the questions in the Workbook.
The Instructor Resources CD contains PowerPoint lecture slides that present the highlights of each chapter, an ExamView computerized test bank, an
electronic version of the Instructor’s Guide, and an Image Library that includes
images from the text.
In the Workbook, each chapter includes a variety of review questions that
correspond with the chapter objectives to provide a comprehensive, in-depth
review of material covered in the chapter.

Questions include sentence completion, multiple choice, and figure-labeling exercises.
The Welding Principles and Practices on DVD series explains the concepts
and shows the procedures students need to understand to become proficient
and professional welders.

Four DVDs cover Shielded Metal Arc Welding, Gas
Metal Arc Welding, Flux Cored Arc Welding, and Oxyacetylene Welding in
detail. The main subject areas are further broken down into subsections on
each DVD for easy comprehension.

The DVD set offers instructors and students the best welding multimedia learning tool at the fingertips.