Welding Merit Badge

The Welding merit badge helps Scouts learn how to join metal using heat. Welding is used in many jobs, like building bridges, making cars, and fixing equipment. When Scouts work on the Welding merit badge, they get hands-on experience with real tools. They also learn how to work safely around hot metal and sparks.

Scouts who earn the Welding merit badge learn how to follow instructions and pay attention to detail. These are useful skills for many careers. Welding takes practice and focus. Scouts learn to be patient and careful. They also gain confidence by trying something new.

The Welding merit badge also shows Scouts how science and math are used in real life. They see how heat and metal work together. They learn about different types of welding and where each one is used. This can help Scouts who are thinking about a future in skilled trades.

Working on the Welding merit badge can help Scouts decide if they like this kind of work. Some Scouts may want to learn more and take welding classes in high school. Others might explore careers in welding or metalwork. This merit badge gives them a strong start.

Welding Merit Badge Requirements

Welding Merit Badge Pamphlet

Welding Merit Badge Workbook / Worksheet

Welding Merit Badge Printable Requirement Check Off Sheet

Checklist for All Merit Badges

Help with Answers for Welding Merit Badge Requirements

Find specific helps for some of the Welding merit badge requirements listed below. Some of these resources will just give the answers. Others will provide engaging ways for older Scouts to introduce these concepts to new Scouts.

• Requirement 1: Hazards
• Requirement 2: Safety
• Requirement 3: Terms
• Requirement 4: Cutting Methods
• Requirement 5: Welding Processes
• Requirement 6: Skills
• Requirement 7: Careers
• More Resources

Staying Safe While Welding

Welding uses very high heat to melt and join metal. This can be dangerous if you are not careful. One hazard is burns. The welding torch makes a hot arc, which is a bright spark between the torch and the metal. This arc can reach temperatures over 6,000 degrees Fahrenheit. Touching the metal too soon or getting too close to the arc can cause serious burns. Always wear gloves, a long-sleeved shirt, and pants made of heavy cotton or leather to protect your skin.

Another hazard is eye injury. The arc gives off very bright light, including ultraviolet (UV) rays. If you look at the arc without protection, you can get something called arc eye. This is like a sunburn on your eyes. It can be very painful. To protect your eyes, always wear a welding helmet with a proper lens shade. This blocks the harmful light while still letting you see your work.

Breathing fumes is also a danger. When metal is heated during welding, it can release gases and small particles into the air. These can be harmful to your lungs if you breathe them in. You should always weld in a space with good airflow. This is called ventilation. Sometimes you may also need to wear a special mask called a respirator if the fumes are strong or the space is small.

Fire is another risk. Sparks from welding can land on clothes or nearby items and start a fire. Always keep flammable materials away from your work area. That means no paper, wood, or oily rags nearby. Have a fire extinguisher close in case something does catch fire. Learning how to watch for these dangers and stop them before they happen is a big part of the Welding merit badge. When you know what to look for, you can stay safe and focus on learning new skills. That’s one reason the Welding merit badge is a great way to explore welding in a safe and smart way.

First Aid and Safety While Welding

Welding can cause injuries if safety rules are not followed. When working on the Welding merit badge, you learn how to prevent these problems and how to give first aid if something goes wrong. It’s important to know how to help yourself or someone else right away.

Here are some common welding injuries or illnesses and how to prevent or treat them:

• Electrical shock – Welders use electricity to create heat. If your skin touches the metal parts of the equipment, you could get shocked. To prevent this, always wear dry gloves and check that your equipment is in good shape. If someone is shocked, turn off the power first. Do not touch them until the power is off. Call for help and check if they are breathing.
• Eye injuries – Looking at the welding arc without protection can cause arc eye. This feels like sand in your eyes and is very painful. Always wear a welding helmet with the right lens shade. If someone gets arc eye, keep their eyes closed and covered. Take them to a doctor.
• Burns – Touching hot metal or getting too close to sparks can burn your skin. Always wear gloves and long sleeves. If you get a minor burn, cool it with water and cover it with a clean cloth. For serious burns, get medical help right away.
• Fume inhalation and dizziness – Welding releases gases and fumes. Breathing them in can make you dizzy or sick. Always work in a well-ventilated area. If someone feels dizzy, get them to fresh air and have them sit down. If they do not feel better, call for help.
• Skin irritation – Welding sparks and UV rays can irritate your skin. Cover all skin with proper clothing. If your skin gets red or itchy, wash it and avoid scratching. See a doctor if it gets worse.
• Exposure to hazardous chemicals – Some filler metals and welding gases can be harmful. A filler metal is the material used to join the metal pieces together. Always read the safety labels and use protective gear. If someone breathes in dangerous fumes or spills chemicals on their skin, follow the instructions on the label and get help fast.

The Welding merit badge helps you learn how to avoid these dangers. It also teaches you what to do if something goes wrong. Knowing first aid is part of being a safe and prepared welder. This is a big reason why safety is such an important part of earning the Welding merit badge.

Learning Safety Rules and Understanding SDS

Welding can be dangerous if you don’t follow safety rules. When you work on the Welding merit badge, you learn how to stay safe every time you weld. General safety precautions help you avoid injuries like burns, shocks, and breathing problems. These rules include wearing the right safety gear, checking your tools before you start, and keeping your work area clean and dry.

One important rule is to always wear personal protective equipment. This includes a welding helmet, gloves, safety glasses, long sleeves, and closed-toe shoes. These protect your skin and eyes from sparks and heat. You should also keep flammable materials away from your work area. That means no paper, gas cans, or oily rags nearby. Always have a fire extinguisher close, just in case.

Another part of staying safe is knowing what chemicals or materials you are using. This is where Safety Data Sheets, or SDS, come in. Every chemical or substance used in welding should have an SDS. These sheets tell you what the material is, what dangers it might have, and what to do if there is an accident. For example, an SDS might explain what to do if a chemical gets on your skin or in your eyes.

The SDS is important because it helps you know how to protect yourself. It tells you what kind of safety gear you need and how to store the material safely. Reading the SDS before using a welding gas or filler metal helps you make smart choices. When you work on the Welding merit badge, you learn how to read and understand these sheets. This helps you become a safer welder and a more responsible Scout.

Dressing the Right Way for Welding

Wearing the correct safety gear is very important when welding. Sparks, heat, and bright light can hurt your skin, eyes, and lungs. The Welding merit badge teaches you how to protect yourself by wearing the right clothing and equipment. You must be dressed properly every time you weld, even for a short job.

The most important piece of safety gear is a welding helmet. This protects your eyes and face from the bright arc and flying sparks. The helmet has a dark lens that blocks harmful light like ultraviolet (UV) rays. UV rays can burn your eyes and skin. Some helmets have auto-darkening lenses that change shade when you start welding. This helps you see clearly before and during the weld.

You also need to wear safety glasses under your helmet. These protect your eyes from flying pieces of metal or sparks when your helmet is lifted. For clothing, wear a long-sleeved shirt and long pants made from flame-resistant material like heavy cotton or leather. Do not wear synthetic fabric like nylon or polyester, because it can melt and stick to your skin.

Welders wear leather gloves to protect their hands from heat and sparks. The gloves should be thick and go past your wrists. You also need strong leather boots with closed toes. Steel-toe boots are best if you are working in a shop where heavy items might fall. Never wear open-toed shoes or sneakers. When working on the Welding merit badge, you will need to show that you understand how to dress properly and why each piece of safety gear is important. This helps keep you safe every time you weld.

Taking Care of Your Welding Gear

Welding tools and safety gear must be kept clean and in good condition. This helps them work properly and last longer. It also keeps you safe. The Welding merit badge teaches you not only how to weld, but also how to take care of your equipment and clothing.

Your welding helmet should be stored in a dry place where it won’t get scratched or damaged. Clean the lens gently with a soft cloth. Make sure the lens is not cracked or loose. If you use an auto-darkening helmet, check the batteries and settings before each use. Never drop your helmet or leave it where it could fall.

Welding tools like clamps, torches, and cables should be kept clean and dry. After each use, check for damage such as frayed wires or loose connections. Store tools in a toolbox or on a rack where they are easy to find and will not get damaged. Keep cables rolled up and off the floor to prevent tripping or damage.

Protective clothing and footwear also need care. Shake out your welding gloves after each use and check for holes. Clean your leather jacket or apron with a damp cloth and hang it up to dry. Store boots in a dry place and keep the soles clean. If they get soaked, dry them out before wearing them again. When working on the Welding merit badge, you show that you understand how to care for your gear. Taking care of your equipment is a key part of welding safely and responsibly.

What Happens During Welding and Key Words to Know

The Welding merit badge helps you understand how welding works. Welding joins pieces of metal using high heat. The process melts the edges of the metal so they can mix and cool into one strong piece. This is different from soldering or brazing, which use lower heat and do not melt the base metal.

Here are some welding terms you should know:

• Welding – A process where metal is melted and joined together using heat. It creates a strong, permanent bond.
• Electrode – A metal rod that carries electricity to create heat for welding. In some types of welding, it also melts and becomes part of the weld.
• Slag – A layer of waste material that forms on top of the weld. It protects the hot metal while it cools. After the weld is done, the slag is chipped or brushed off.
• Oxidation – A chemical reaction that happens when hot metal touches oxygen in the air. It can make the weld weak or dirty. Welders try to protect the hot metal from the air to stop oxidation.

Heat for welding is made by electricity. In electric arc welding, the heat comes from an electric arc. This arc forms between the tip of the electrode and the metal being welded. The arc is very hot and melts the metal quickly. This melted metal is called the weld pool.

Many welding methods use a filler metal. This is a metal that melts and mixes with the base metal to help fill the gap between the pieces. In stick welding, the electrode itself is the filler metal. In other types like MIG welding, a separate wire is fed into the weld as the filler.

The molten metal must be protected from the air. Oxygen and other gases can cause oxidation and weaken the weld. To prevent this, welders use shielding. In stick welding, the coating on the electrode burns and creates a gas that shields the weld. In other types, like MIG or TIG welding, a shielding gas flows around the weld to protect it.

Learning these terms and how the process works is a big part of the Welding merit badge. Knowing how to control heat, use filler metal, and protect your weld from the air helps you make strong and clean welds. These basics help you understand and enjoy the skill of welding.

Ways to Cut Metal: Mechanical and Thermal Methods

When working with metal, sometimes you need to cut pieces before or after welding. The Welding merit badge teaches about different ways to do this. Cutting methods fall into two main groups: mechanical and thermal. Each method has its own use, advantages, and limits.

Mechanical cutting uses tools that physically remove metal. Common mechanical cutting methods include sawing, shearing, grinding, and using cutting wheels. These methods do not use heat. They are good for straight cuts and when you want to avoid heating the metal. Mechanical cutting is often slower and may not work well on thick or very hard metal.

Thermal cutting uses heat to melt or burn through metal. Common thermal cutting methods are oxy-fuel cutting, plasma cutting, and laser cutting. These methods use a flame, gas, or electrical energy to cut metal quickly. Oxy-fuel cutting uses a torch with fuel gas and oxygen to burn through steel. Plasma cutting uses electricity and gas to create a very hot arc that melts the metal. Laser cutting uses a focused beam of light to melt and cut the metal.

Each method has advantages. Mechanical cutting is safer and simpler for beginners. It does not create sparks or fumes. But it can be slower and may not cut thick metal easily. Thermal cutting is faster and can cut thick or complex shapes. But it creates heat, sparks, and fumes, so you need more safety gear and training. The Welding merit badge helps Scouts understand when to use each method and how to stay safe while cutting metal. This knowledge is helpful for welding projects and other metalwork.

Different Welding Methods and What They Use

The Welding merit badge introduces Scouts to different types of welding. Each welding process uses different tools and has its own strengths and weaknesses. Knowing the equipment and when to use each process helps you choose the right one for the job.

Shielded Metal Arc Welding (SMAW or Stick Welding)
This is one of the most common welding methods. It uses a power source, an electrode holder, a ground clamp, and stick electrodes. The electrode is a metal rod covered in flux. The arc melts the electrode and the base metal, and the flux creates a gas that shields the weld.
Advantages: It works well outside and on rusty or dirty metal. The equipment is simple and easy to move.
Limitations: It creates slag that must be cleaned off. It is harder to weld thin metal with this method.

Gas Metal Arc Welding (GMAW or MIG Welding)
This method uses a welding machine, a wire feed system, a welding gun, and a cylinder of shielding gas. A wire electrode feeds through the gun and melts into the weld. The gas protects the weld from the air.
Advantages: It is faster and easier to learn than stick welding. It creates clean welds with less spatter.
Limitations: It doesn’t work well outside because the wind can blow away the shielding gas. The equipment is heavier and more complex.

Gas Tungsten Arc Welding (GTAW or TIG Welding)
This process uses a power source, a torch, a tungsten electrode, a foot pedal, shielding gas, and sometimes a filler rod. The tungsten does not melt. It creates the arc, and you add filler metal by hand.
Advantages: It makes very precise and clean welds. It works well on thin metal and non-ferrous metals like aluminum.
Limitations: It is slower and harder to learn. The equipment is more expensive and takes more skill to use.

When earning the Welding merit badge, Scouts learn the basics of these welding types. They also learn what tools are needed and what each process is best for. This helps Scouts understand welding better and prepare for hands-on experience.

Getting Ready to Weld: Setting Up Your Work Area

Part of earning the Welding merit badge is learning how to set up your equipment correctly. A good setup helps you weld safely and do better work. Before you begin, choose the welding process you want to use, like MIG welding or stick welding. Make sure your work area is clean, dry, and free from anything that can catch fire, such as paper, oil, or rags.

For most welding processes, you need several basic parts: a welding machine, power cables, a ground clamp (also called a work clamp), and an electrode or wire. If you are using MIG welding or TIG welding, you also need a gas cylinder and gas regulators. The gas protects your weld from the air. Connect the gas hose to the regulator and adjust the flow to the right setting, which is often around 20 to 25 cubic feet per hour, but it can vary.

Attach the ground clamp to a clean part of the metal workpiece. This completes the electrical circuit. Connect the welding gun or electrode holder to the power source. Set the correct voltage or amperage for your type of weld and the thickness of the metal. Use the chart on the machine or ask your counselor for help. Make sure your filler material, like welding wire or stick electrodes, matches the metal you are working with.

Before starting any weld, ask your counselor to check your setup. They will make sure everything is connected correctly and safely. This includes checking that the gas is flowing, the clamp is secure, and the settings are right. Taking time to prepare your area the right way is an important part of the Welding merit badge. It helps prevent accidents and lets you focus on learning the skill of welding.

Practicing Welds: Building Skills with Real Welds

After you have set up your equipment and gone over safety and tools, the Welding merit badge asks you to try real welding. These hands-on tasks help you build skill and confidence. You will practice drawing and welding, laying down beads, and joining metal in different ways. This gives you a solid foundation in basic welding work.

Start by using a metal scribe or soapstone to draw the first letter of your name on a piece of steel. A scribe is a sharp metal tool used to mark lines. Soapstone is a soft white stone that leaves clear marks on metal. Once your initial is marked, follow that line with your welding torch to lay down a weld bead. A bead is a line of melted filler metal made as you move along the joint.

Next, take a small metal plate and cover it with weld beads laid side by side. Try to make each bead straight and even. This helps you learn to control the torch and move at the right speed. Then, take two metal plates and tack them together. A tack weld is a small weld that holds the pieces in place before the full weld. Use a square groove butt joint, which is when two flat edges are lined up and joined. After tacking, weld both sides of the plates.

The Welding merit badge also asks you to practice two more joints. First, make a T joint, where one plate stands up like the letter T against the flat plate. Tack it, let your counselor check it, and then weld both sides with a fillet weld. A fillet weld fills the corner between two metal surfaces. Then do a lap joint, where one plate overlaps the other. Tack it, have it inspected, and weld both sides with fillet welds. These welds are common in many projects. Doing these tasks helps you understand real welding work and prepare for bigger projects later on.

Exploring Welding Careers

When working on the Welding merit badge, Scouts learn that welding is a useful skill in many careers. Some welding jobs involve building large structures, while others focus on detailed and careful work. Here are some careers in the welding industry to explore:

• Structural Welder – Builds and repairs buildings, bridges, and large metal structures. Often works outdoors and on construction sites.
• Pipe Welder – Joins metal pipes used for water, oil, and gas systems. Must make strong welds that don’t leak.
• TIG Welder – Uses gas tungsten arc welding (TIG) for clean, precise welds. Often works on thin or special metals like aluminum and stainless steel.
• MIG Welder – Uses gas metal arc welding (MIG) for fast and clean welds. Works in factories, auto shops, and on production lines.
• Underwater Welder – Does welding jobs under water, often for ships, oil rigs, or docks. Requires extra training in diving and welding.
• Welding Inspector – Checks other welders’ work to make sure it is safe and meets rules. Must know welding standards and testing methods.
• Welding Instructor – Teaches welding in schools or training centers. Helps new welders learn safety, equipment, and welding skills.
• Welding Engineer – Designs welding plans for projects. Works with blueprints and helps choose the right welding process and materials.

The Welding merit badge gives you a chance to try welding and see if it’s something you enjoy. If you like it, there are many careers where you can use welding to build, repair, and create things.

The American Welding Society and Its Importance

The American Welding Society, or AWS, is a group that supports the welding profession. It was started in 1919 to help improve welding and support people who work in the welding field. The AWS sets standards, offers training, and helps welders stay up to date on new skills and tools. When you earn the Welding merit badge, you learn about the importance of groups like AWS in the welding world.

One big job of the AWS is creating welding codes and standards. These are the rules that tell welders how to do their work safely and correctly. These rules are used in construction, factories, and shipbuilding to make sure welds are strong and safe. If welders do not follow these codes, the parts they build might not hold up under pressure or over time.

The AWS also offers certifications. A certification is a way to prove that a welder has the skills to do a certain type of welding. Many employers look for welders with AWS certification. To earn one, you must pass a hands-on test and sometimes a written exam. The AWS has certifications for many welding types, such as structural welding, pipe welding, and welding inspection.

The AWS helps welders learn and grow in their careers. It offers classes, books, and online training. The group also hosts events where welders can meet others in the field, learn new things, and see new tools. When you work on the Welding merit badge, you learn how the AWS helps keep welding safe and professional. This can be helpful if you decide to explore welding as a job in the future.

More Merit Badge Resources

​Scouts BSA offers over 100 merit badges that allow Scouts to explore various subjects, including sports, crafts, science, trades, business, and potential careers. Scouts can pursue any merit badge at any time, regardless of their current rank. The badges cover a wide range of topics, such as outdoor skills, health and safety, information technology, and fine arts. For instance, the Welding merit badge introduces Scouts to the fundamentals of welding, emphasizing safety and practical skills.

To earn a merit badge, Scouts select a topic of interest, obtain a signed application from their Scoutmaster, and contact an approved counselor. They then work on the requirements, which may involve research, skill development, or projects. After demonstrating their knowledge and skills to the counselor, the completed application is submitted to the troop advancement chair. The Welding merit badge, like others, provides hands-on experience and valuable knowledge in its respective field.

Learn More about Scouts BSA

Scouts BSA is a program for youth aged 11 to 17. It focuses on character development, citizenship, and personal fitness through activities like camping, hiking, and community service. Scouts progress through ranks, starting with Scout and advancing to Eagle Scout, by learning skills and earning merit badges. For example, the Welding merit badge introduces Scouts to metalworking techniques and safety practices.​

The program uses the patrol method, where small groups of Scouts work together, promoting teamwork and leadership. Scouts BSA is inclusive, welcoming members from diverse backgrounds. By participating, Scouts gain confidence, resilience, and practical skills. Earning merit badges, such as the Welding merit badge, allows Scouts to explore potential careers and hobbies.​

What is the Welding merit badge about?

The Welding merit badge teaches Scouts how to weld metal safely. Scouts learn how to set up equipment, make different kinds of welds, and follow safety rules.

Do I need to have welding experience before starting the Welding merit badge?

No. You do not need any experience. You will learn the basics during the badge.

What kind of welding do Scouts use for the Welding merit badge?

Most Scouts use stick welding or MIG welding. These are good for beginners and are used in many jobs.

Is welding dangerous?

Welding can be dangerous if safety rules are not followed. The Welding merit badge teaches you how to stay safe with the right gear and careful setup.

What safety gear do I need for the Welding merit badge?

You need a welding helmet, safety glasses, gloves, long sleeves, long pants, and closed-toe boots.

What kind of projects will I do for the Welding merit badge?

You will draw your initial on a metal plate and weld it. You will also make weld beads and join metal plates using different welds.

Can I do the Welding merit badge at home?

Most Scouts earn the Welding merit badge at a welding shop or camp where trained adults and the right tools are available.

Is the Welding merit badge useful for future jobs?

Yes. Welding is used in many jobs. This badge can help you decide if you want to learn more or work in the welding field.

Do I need to bring my own tools?

Usually, tools and gear are provided at the place where you work on the Welding merit badge. Ask your counselor what to bring.

Who can help me earn the Welding merit badge?

A merit badge counselor who knows welding will guide you. They will help you learn, check your work, and make sure you are safe.

The Welding merit badge teaches Scouts how to safely join metal using heat. It covers both the science and the skill of welding. Scouts learn about safety gear, setting up equipment, and how to protect themselves while working. They also learn how to prepare metal, lay weld beads, and join pieces using different types of welds.

This merit badge includes hands-on practice. Scouts draw their initials on metal and weld over the markings. They cover a plate with weld beads and join metal plates in several common ways, like butt joints, T joints, and lap joints. Each step builds skill and confidence.

Scouts also learn welding terms, first aid, and how to read Safety Data Sheets. They find out how to care for tools and explore jobs in the welding field. The Welding merit badge is a great choice for Scouts who like working with tools and building things. It can also be a first step toward a career in welding.