TM 1-1500-204-23-8 Change 1          3-1 CHAPTER  3 WELDING SHOP PRACTICES 3-1.  General.    Welding is the process of joining  metal by fusing the materials while they are in a molten state. The following general paragraphs describe welding shop rules,  types  of  welding,  welding  materials,  aluminum welding, magnesium welding, corrosion-resistant steel and nickel- chromium-iron alloy welding, welding on air- craft, and brazing and  silver soldering. 3-2.  Shop  Rules.       The   practices   and   procedures described in this chapter pertain to the manufacturing and repair functions of aviation activities and are applica- ble to all levels of maintenance. Because of the many types of Army aircraft, each shop within the manufactur- ing and repair section must, of necessity, have personnel trained in general practices and procedures to the extent that  different  type  and  model  aircraft  do  not  upset  a smooth running shop. a.  Responsibility.  All    supervisory    personnel    are responsible for a continuing and effective shop safety program. To implement and maintain this program, shop supervisors  will  utilize  bulletin  boards,  signs,  and  any other effective method. Shop personnel will cooperate in the shop safety program by making helpful recommen- dations, and continually exercising care and caution in the operation of all shop equipment. All shop personnel will strive to improve the safety program and be espe- cially alert to observe and correct hazardous conditions and unsafe shop practices. All accidents, no matter how minor, shall be reported to the shop supervisor, and all published instructions regarding safety shall be strictly adhered to. Also, safety engineers and safety officers will ensure that proper safety procedures are adhered to in accordance with AR 385-10, Army Safety Program. The Occupational  Safety  and  Health  Act  of  1971,  OSHA 1910.251; all applicable fire codes, NFPA 410; and other accepted civilian and military safety practices. b.  Shop Housekeeping.  Housekeeping is the yard- stick by which the shops are judged. A clean, well-ar- ranged  shop  is  a  safe  shop  and  reflects  credit  on  all personnel  concerned  with  its  operation.  The  following shop practices shall be observed: (1) Oil pans or drip pans shall be used where leaking  oil,    grease,  and  similar  materials  may  cause hazardous  accumulations  on  equipment  or  floors.  All spills shall be cleaned up immediately. Approved sweep- ing compound may be used to remove these materials from the floor. CAUTION Floors  shall  not  be  cleaned  with  volatile  or flammable  liquids.  Fire  hazard  which  may damage equipment may result. (2) Floors   shall   be   maintained   smooth   and clean, free of all obstructions and slippery substances. Holes  and  irregularities  in  floors  shall  be  repaired  to maintain a level surface free from tripping hazards. (3) All unnecessary materials on walls shall be removed and projections shall be kept to a minimum. (4) Aisles shall be clearly defined and kept free of hazardous obstructions. Where possible, aisles shall be suitably marked by painting. (5) All  machines,  work  benches,  aisles,  etc., shall be adequately illuminated. c.  Safety.  The various types of welding operations create numerous health and fire hazards unless proper precautions are exercised. The harmful light rays pro- duced by welding flames and arcs may seriously injure the eyes and burn the skin. Poisonous fumes and gases which may cause serious illness are produced in welding operations. The skin may be burned by splashing metal, hot sparks, welding flame or arc, and hot objects which are handled. Severe electric shock is possible from elec- trically  powered  welding  apparatus.  The  flame-  and heat-producing aspects of welding create a serious fire and explosion hazard wherever welding is done in the vicinity of flammable liquids and gases. In view of the numerous possibilities for injury and damage in welding operations, it is essential that safe practices and stan- dards  be  observed.  The  following  paragraphs  explain welding safety practices.