Arc Welding Machine Hazards: What Risks Arise from Faulty Lugs?

I would like to know the entire hazards of an arc welding machine and their risks.

Potential Risks of Improper Welding Machine Lugs

Q) If the welding machine lugs are not proper, what may happen (leading to which risk)?

Warm Regards,
S.S. Jakeer Hussain.

If the welding machine lugs are not properly tightened, it may cause an electrocution hazard, and the welding quality will not be good. You can use damaged cables to cover and overlap the working cable lugs joint with double tapping.

Thank you.

Understanding the Impact of Improper Electrical Connections

I hope you have some knowledge of electrical installation. Please check what happens when there is an improper contact or connection. When the line or equipment is energized, there will be a chance of heavy sparks at that point. Every time this occurs, more current will flow, and momentarily, the voltage will increase manyfold. Additionally, at these points, there is a chance of carbon deposits forming. Where carbon gets deposited, the area becomes blackened and requires more current, eventually causing the metal to deteriorate. This situation leads to an increase in current flow and various other issues related to the improper lugs.

Apart from safety concerns, it also affects welding quality due to variations in current and voltage.

Regards,
Kesava Pillai

Hope you got your answer. Lugs/thimbles play a very important role in welding operations. Hats off to Kesava Pillai for his excellent explanations all the time. If lugs are damaged, there is a great risk of electrocution and also a chance of fire. On the other hand, the quality of work will be compromised due to improper lugs or connections.

If you need a brief explanation, please refer to OSHA 1926 Subpart J 'Title Welding.'

Regards,
Yousuf Ali (Sr. EHS Officer)

If there is not a proper connection of welding machines, there may be fire or sparking from the lugs, overheating, cable damage, electrocution, electric burns, and poor quality work.

Thank you.