I'm trying to figure out how to be able to use one ratchet strap to secure the cylinder to the cradle and the tie downs in the bed at the same time. I...
I don't like the round dies for the simple reason that you gotta use that stupid handle. With the hex ones, you can use a ratchet and socket or wrench, ...
It's infinitely better than the guy driving down the road with a cylinder tucked against the cab secured with a bungee cord. -_-
Not to mention only t...
Lysholms sadly where not in the budget, i will be using a modified Gen3/4 hybrid Eaton M62 Roots that will give me 330 extra CFM. i good place to star...
Don't feel too bad. We had enough spare gear in the back of the work truck to do half a week's worth of plumbing / fitting jobs on spare parts and po...
Welding Your Own Shelves
When it comes to welding, you really do need a safe, clean work area. It just won’t work to have flammable liquids around when the sparks start to fly.
Thankfully, even a welder new to the trade can manage enough tacks and joints to create strong, functional metal shelves in a garage that are suitable for storing anything you dig up, bring home from the store, or purchase online. Heavy welding machines, scrap metal, and saws can find a suitable spot in homemade, metal shelves that you’ve welded with your own hands. In fact, you may even have some scrap metal laying around that you can use for this project.
While purchasing all of the materials new may be a little costly, you can’t place a cash value on being able to custom design shelves that meet your specific needs and space constraints. In addition, you’ll feel better about having designed and built the shelves in your own work area when you enter your garage or work shop ready to get down to business.
Welding Steel Before Galvanizing
01.26.12
A diversity of steel fabrication sizes and configurations are well suited for galvanizing. Throughout North America, variously sized hot-dip galvanizing kettles are available, allowing this broad scope of structural fabrications to be galvanized.
Unless the welded structure will be too large for the galvanizing kettle, it is common practice to weld steel before galvanizing. Welding steel prior to galvanizing ensures that the entire structure is coated with corrosion-inhibiting zinc.
As with any fabrication to be galvanized, it is important for the steel’s surfaces to be entirely free of residues commonly found on steel, including weld flux. To make this objective easier to meet, when welding prior to galvanizing an uncoated electrode should be used to prevent flux deposits. If using a flux-coated electrode is unavoidable, mechanical cleaning methods will be needed to prepare the steel for galvanizing.
Submerged arc welding (SAW)
01.16.12
Submerged arc welding (SAW) is so named because the weld and arc zone are submerged beneath a blanket of flux. The flux material becomes conductive when it is molten, creating a path for the current to pass between the electrode and the workpiece. The flux blanket prevents spatter and sparks, while shielding ultraviolet light and fumes that are normally a part of shielded metal arc welding. The flux usually is supplied to the welding head via a small hopper. A collection system gathers the excess flux for reuse.
The process uses one or more continuously fed electrodes (wires) to maintain an arc. SAW is known for its ability to deposit large amounts of metal quickly, consistently, and safely. The basic SAW equipment is a power source, control unit, wire unit, and nozzle.
Flux cored welding wire
01.12.12
Flux cored welding wire is available for both mild steel and stainless steel Gas Metal Arc Welding (GMAW or MIG). A flux cored wire is a tubular wire with a metallic powder flux inside. The primary advantage to flux cored wire over GMAW or stick welding is higher deposition rates, deeper penetration, improved bead appearance and is more cost effective.
The make-up of the flux has a dramatic effect on the weld process. Flux cored wires are available as a gasless or gas shielded wire. The advantage of the gasless wire is that is can be used outdoors without the threat of the shielding gas being "blown away" by the wind. The weld has a thick flux coating on it when it cools which can be easily removed. The gas shielded flux cored wire allows the operator the advantages of different flux types within the wire. The gas shielded flux cored wire generates a thin flux coating on the finished product which can be easily removed. Flux cored wire is available in diameters ranging from .030 - .125 in many spool sizes.
Stick Welding Tips on Advantages and Limitations
01.11.12
Shielded Metal Arc Welding (SMAW) is one of the oldest practical processes that uses electrical energy as the power source, and it is still one of the most widely applied. It evolved in time, with the progress in understanding the functions of the ingredients in the shielding cover, to the point where it stands now as the baseline process to which all other processes are compared.
Among SMA-welding-tips one should remember that this is the process that uses an electric arc between a covered electrode (stick) and the work, melting base and filler metal to produce the weld.
The electrode cover, heated by the arc, decomposes and evolves shielding gases that protect the weld pool and the hot metal and leaves a solid slag cover that prevents the weld from being oxidized while still hot and contaminated by contact with the surrounding air.
SMA-welding-tips on Advantages
Suitable for a large variety of metals
Equipment relatively simple, economic, portable
Electrode provides both filler metal and shielding means
Favorable for reaching limited access spots
Flexible, applicable to different joint configurations and welding positions
Reliable and consistent good results
Applicable to underwater welding
Semi automatic with gravity feed and firecracker welding
Suitable for outdoor welding
SMA-welding-tips on Limitations
MIG WELDING TIPS AND TRICKS
01.09.12
Obviously it’s safety first when you’re learning to weld. That is common sense, but I say that so you’re sure to remember: welding is dangerous. Welders throw sparks; they set things on fire. Make sure anything in the area around you that could possibly ignite is removed. If you are outside, near grass or bushes, wet them with a hose.
Some welding safety tips:
Your skin—and your hair—can burn. Wear a long sleeve shirt, long, non-flammable pants without cuffs and leather welding gloves. - A good eye shield or welding hood must be used.
Keep a fire extinguisher near you when you are welding.
Don’t Mig or arc weld where water is in contact with you or your welding surface. You risk electrocution if you do.
Use proper ventilation when you weld. Harmful fumes are generated, and you need ventilation.
Practice welding, then practice more
When you are ready to start, practice welding on scrap metal that is close to the thickness of the metal you are going to repair. This is usually 20 or 22 gauge “stock material” which is available at metal scrap yards.
In welding, practice is essential and it will show up in your final effort. You definitely want your technique in place before you weld a live project on valuable metals, a car, or other items.
TIPS FOR WELDING SHEET METAL ON CARS
01.06.12
When welding a patch panel or fender flare on a car, I use either oxy-acetylene (gas welding) or wire-feed (mig welding), in that order of preference. Tig welding is great, but few do-it-yourselfers have a tig welder, so we’ll stick with the first two. Gas welding is my first choice because the metal stays fairly soft and workable, and metal-finishing is easier (and more quiet). Mig welding work-hardens the metal and seems to shrink the weld area excessively. Gas welding also shrinks (heat shrinks); however, the metal is still workable with hammer & dolly, whereas a mig-welded panel is too stiff to work effectively.
Gas Welding: As a good rule of thumb, gas-weld the panels you can reach both sides of; mig-weld where access is more limited. I sometimes do both on a panel. If you choose this method, be aware that it’s easier to mig-weld over a gas-weld than vice-versa, so do the gas-welding first (at least where the welds join). When gas-welding, I use the smallest tip I can get away with, usually a 00 or 000, and low line pressures. If the torch pops when welding, the pressure may be too low, the tip may be too large, or the tip may be dirty. If the torch is noisy, the problem might be, high line pressure, too small a tip, too much oxygen, a dirty tip, or a combination of these.
Your weld-puddle should look smooth and glassy. If your weld falls through, you’re too hot; if it takes more than a few seconds to get a puddle going, you’re too cold. If your torch acts up once you’re set up the way you like, the problem is usually a dirty tip. Try welding two pieces of 20 gage steel together. Connect the pieces together edge-to-edge (butt weld). If your heat is right and you have a perfect fit, you can fusion-weld them. Fusion-welding is basically melting the metal together, without using filler-rod. You can make beautiful little welds this way. I usually fusion-tack my panels together and use a little filler-rod when finish-welding, to keep from having a concave (shallow) weld surface.
Check the back-side of your weld to make sure you’re getting good penetration. It should look like a weld, not two edges glued together. If you didn’t get good penetration, you can fusion-weld over the bad spots from the back. This exercise will help you make good welds later, when you can’t see the back-side of your work. Remember, heat shrinks, so stretch your tacks with a hammer & dolly; the same applies when finish-welding. After 1/2” to 3/4” (as you get more experienced, you may decide to weld several inches at a time), set your torch down (turned off or in a safe holding bracket), and use your hammer & dolly. The object is to remove some of the shrinking you’ve caused by welding, while keeping your panel in shape. Don’t stray too far from the weld to begin with. You’ll find you can get your shape back if you patiently work the weld area first, and then address any peripheral warpage. Remember, if your panel fits well to begin with, you should be able to make it fit when you’re finished, without resorting to drastic measures. Here is an excerpt from the directions that I send out with my shrinking disc. This may help a little with metal-finishing:
Dent repair and metal-finishing: To repair a dent, use a dolly to bump up the low spot from behind. Some larger dents are best worked from the perimeter in. Bumping with a dolly will bring the dent back near the original contour. This simple step is important throughout the repair, because, in addition to the inevitable small areas that need minor stretching later in the process, you will probably find low spots that just need bumping up. After bumping the dent up to its original contour, start working the metal off-dolly. This means pushing up with a dolly on low spots while hitting high spots with a hammer or slapper. This will start to get the panel smoother. Now start some medium-force on-dolly work. Usually, on-dolly work is stretching the metal between the hammer and dolly but, in this case, very little stretching is done, especially if you use a slapper instead of a hammer, as the force of the blow is spread more evenly. You are using multiple hits to planish (smooth) the area. Now check the shape of the panel. Use templates taken from the same spot on the other side of the car wherever possible. Use one up and down, and another front to back to see where the shape is too low or too high. Sometimes the whole area will still be too low and need more bumping and hammer-and-dolly work. Once you are satisfied that the general shape is right, you can start to pick up specific low spots by stretching on-dolly. Use a dolly that has a slightly higher crown than the panel being worked, and a hammer with a slight crown in it. This way there is a small contact area between the hammer and dolly, making it easier to stretch small areas up. You must push up fairly hard on the dolly. You should see small marks on the metal where it is stretched by the blows. Lightly file the area to show the highs and lows, then repeat the hammer-and-dolly steps, and file lightly again until you have the whole area smooth but a little too high. As an alternative to stretching up the low spots with a hammer and dolly, a tool called a bullseye pick [available from Ron Covell on my links page] can be modified to work very well. It is a little easier to use and may be easier on your arms if you have a lot of work to do. The tip must be ground down so that it is not so sharp, otherwise it will damage the panel. A tip I picked up from Wray Schelin: During metal-finishing, use a large magic marker (“Magnum” size) to ink the whole repair area before filing. This really makes the low spots stand out, just like using a guide coat for sanding primer. For more about metal-finishing from a different perspective, please see the Jag Lovers articles written by Wray Schelin, also on my links page. “The Key to Metal-Bumping” by Frank Sargent is a good resource booklet as well. (The above mentioned links are on the links page of the www.ghiaspecialties.com site.)
Using the shrinking disc: Once you have the metal smooth but high, start running the disc over the surface, back and forth, while moving sideways slightly after each pass - basically a zig-zag pattern, much like what you would use when conditioning a panel with a sander. For most applications, a 6” x 6” area of coverage is a good starting point. Small high spots will turn blue. Stop immediately and use a wet rag to quench and cool the metal. Do not rush! There is no hurry. I keep a rag in the bottom of a bucket with about an inch of water in it so it doesn’t splash much when I drop the rag in after use. The smoother the panel is, the longer you can run the disc without turning any part of the panel blue. It is not necessary to use the disc until the metal turns blue in order to shrink; use it just long enough so that when you quench it with a wet rag it steams. This will take practice to gain the experience of knowing when to stop. Run your hand over the metal both up and down and back and forth to feel the surface while it is still wet. You will be able to tell where the high spots are, and use the disc for a shorter period of time to shrink specific areas. The disc will mark the metal and show the low spots as unmarked. Do not hesitate to go back to some of the previous steps of on-dolly stretching or using the bullseye pick to raise low spots. You may find it necessary to bump up some low spots, or even go back to some off-dolly work. This is part of the process. Once you have done an operation, never assume that it can’t be the problem. Always let the panel dictate what needs to be done. Most severe damage will require multiple passes of the shrinking disc interspersed with quenching, hammer-and-dolly work, and/or the bullseye pick. Once you have the panel nice and smooth, you can spray a guide coat on it, or use the Magnum marker, then sand with an appropriate sanding block with 80 grit to help show small discrepancies. At this stage, you can use a worn-out Scotch Brite pad on a 7” Velcro backing pad fitted to your sander, just as you would the shrinking disc, then quench, to simultaneously polish the surface and shrink a little more as well.
Mig Welding: Most people who have just started mig-welding, seem to have a hard time seeing the weld as they go. If you’re having this problem, make sure the clear lenses protecting your weld lens are new. Also, try using the trigger to do a puddle, then let go of the trigger, move the gun slightly, and repeat this process over and over as you move along. This way, you won’t feel like the machine is forcing you to go too fast. You may find this method helps the quality of your welds, too.
Don’t hesitate to play with the weld settings on your machine; that’s what they’re for. Is your gun jumping? …getting lots of sparks? Your wire speed is probably too high in relation to the voltage. Blowing holes in your work (even with the stop & start method described earlier)? …welds look like lava flows? Your voltage is probably too high, in comparison with your wire speed, or your voltage and wire speed are both too high. Lumpy-looking welds? You should be welding hotter (more wire speed and voltage).
Tack Welding: Take your time, and use lots of tacks; not only do they hold your panel in place, they also help dissipate the heat evenly. The best results are achieved when you insert the panel flush with the car body, instead of overlapping, and less grinding and filler will be required. If you have to push the panel into place to tack it, you will have more of a problem with distortion than if you make the panel fit better to begin with. Tack about every inch or so. If you grind the tops off the tacks, you may have an easier time making a good final weld.
Finish Mig Welds: When doing your final welding, weld only one small hot tack at a time. Do not weld in an area that is warm to the touch. The more heat you put in one place with a mig welder the more leverage the warpage has. When finished, grind the weld as smooth as possible, then sandblast the area. If you don’t have a sandblaster, carve all the scale out of the welds using a small broken drill bit held at an angle in your drill motor. You want shiny metal. When you need filler over welds (usually the case with mig-welding), your first application should be a fiberglass-reinforced filler, as it is tougher and shrinks less than regular filler.
Some Final Tips: Use templates on any shape that isn’t flat. Take the time to protect your eyes, ears, and lungs. Keep a fire extinguisher handy, and keep a fire watch on your shop at least ½ hour after welding.
TIG WELDING GTAW GUIDE
01.05.12
We believe that even experienced welders may occasionally forget those Tig-welding-tips features they do not use often enough, so that a few moments dedicated to this page will refresh basic knowledge that adds to your skill and performance.
The Gas Tungsten Arc Welding (GTAW) also called Tig has the following
Advantages
High quality welds, low distortion
Easy to mechanize and automate
Flexibility and ease of heat control
All metals, all positions
and Limitations
Lower deposition rates
Good skills required
Sensitive to cleanliness and contamination
Arc blow sensitive
Tig-welding-tips: Polarity
The Tungsten Electrode in Gas Tungsten Arc Welding (GTAW or Tig) can make contact with a Direct Current (DC) power supply either at the positive (+) or at the negative (-) terminal. In the first case the connection is for DCEP (electrode positive) or reverse polarity. In the second one for DCEN (electrode negative) or straight polarity.
The heat generated in the electric arc is not distributed uniformly.
Tig-welding-tips - In DCEP:
30% of the heat is concentrated in the workpiece
70% of the heat in concentrated in the tungsten electrode
Shallow penetration
Wide weld area
Tig-welding-tips - In DCEN:
70% of the heat is concentrated in the workpiece
30% of the heat is concentrated in the tungsten electrode
Deep penetration
Narrow weld area
As a consequence of heat distribution, for the same current one has to select in DCEP a larger electrode size than what is proper for DCEN.
Due to the electrode limited current carrying capacity (about 1/10 of DCEN), DCEP is used only for welding thin sheet metal where low current is sufficient.For most other applications welded with higher currents, DCEN is selected if welding other materials than aluminum or magnesium (see below).
Tig-welding-tips: one of the factors of the DC Electrode Negative staying cooler is the evaporation of the emitted electrons, actively contributing to electrode tip cooling.
Tig-welding-tips: Pulsed DC
Advances in electronic controls of power supplies permitted to introduce new wave forms, generally with electrode negative, characterized by current pulsed between a low maintenance or background value, that keeps the arc but allows the weld to cool somewhat, and a high peak value capable of melting metal in a controlled way while ensuring the required penetration.
Tig-welding-tips: This type is called officially GTAW-P, where P stands for Pulsed. The result is better control of the weld puddle without unduly high heat input. Adjustments include both current levels and pulse duration time for each level.
Welding of thin metals or joints of dissimilar thicknesses or dissimilar alloys for manual, mechanized or automatic setups are common applications.
A variant of this process, involving high frequency switching, is useful for precision mechanized and automatic applications where directional properties (stiffness) and stability of the arc are important. Here the current is varied between the two levels as before, but at a selectable fixed high frequency, permitting the resulting low average current.
Read on for more Tig-welding-tips.
Tig-welding-tips: Alternating Current (AC)
In Alternating Current (AC) polarity is inverted at every cycle. The frequency is 50 hertz or cycles per second in Europe and 60 Hz in the USA. In the standard transformer power supply the heat of the arc, because of alternant polarity, is evenly distributed between electrode and workpiece. The results of penetration depth and weld width are somewhat intermediate between DCEP and DCEN.
Tig-welding-tips: Using AC one profits from the cathodic cleaning action (of electrons being emitted by the workpiece towards the electrode) during the half cycle when the electrode is positive (EP). This action, that removes oxides from the surface of the metal, is essential for welding aluminum and magnesium.
Furthermore the higher setting value of Alternating Current provides, for every half cycle, deeper penetration than what would be possible with DCEP at lower current values. Practically the alternating current carrying capacity of a given tungsten electrode of a certain size is about one half of the DCEN it could carry.
Tig-welding-tips: A power supply transformer connected to the power grid would provide arc extinction at every half cycle. Reestablishment of the arc is easy when the electrode is negative, but almost impossible (except for quite high open circuit voltage) when the electrode is positive.
Tips and Tricks for Welding Sheet Metal
12.26.11
When welding a patch panel or fender flare on a car, I use either oxy-acetylene (gas welding) or wire-feed (mig welding), in that order of preference. Tig welding is great, but few do-it-yourselfers have a tig welder, so we’ll stick with the first two. Gas welding is my first choice because the metal stays fairly soft and workable, and metal-finishing is easier (and more quiet). Mig welding work-hardens the metal and seems to shrink the weld area excessively. Gas welding also shrinks (heat shrinks); however, the metal is still workable with hammer & dolly, whereas a mig-welded panel is too stiff to work effectively.
Gas Welding: As a good rule of thumb, gas-weld the panels you can reach both sides of; mig-weld where access is more limited. I sometimes do both on a panel. If you choose this method, be aware that it’s easier to mig-weld over a gas-weld than vice-versa, so do the gas-welding first (at least where the welds join). When gas-welding, I use the smallest tip I can get away with, usually a 00 or 000, and low line pressures. If the torch pops when welding, the pressure may be too low, the tip may be too large, or the tip may be dirty. If the torch is noisy, the problem might be, high line pressure, too small a tip, too much oxygen, a dirty tip, or a combination of these.
Your weld-puddle should look smooth and glassy. If your weld falls through, you’re too hot; if it takes more than a few seconds to get a puddle going, you’re too cold. If your torch acts up once you’re set up the way you like, the problem is usually a dirty tip. Try welding two pieces of 20 gage steel together. Connect the pieces together edge-to-edge (butt weld). If your heat is right and you have a perfect fit, you can fusion-weld them. Fusion-welding is basically melting the metal together, without using filler-rod. You can make beautiful little welds this way. I usually fusion-tack my panels together and use a little filler-rod when finish-welding, to keep from having a concave (shallow) weld surface.
Check the back-side of your weld to make sure you’re getting good penetration. It should look like a weld, not two edges glued together. If you didn’t get good penetration, you can fusion-weld over the bad spots from the back. This exercise will help you make good welds later, when you can’t see the back-side of your work. Remember, heat shrinks, so stretch your tacks with a hammer & dolly; the same applies when finish-welding. After 1/2” to 3/4” (as you get more experienced, you may decide to weld several inches at a time), set your torch down (turned off or in a safe holding bracket), and use your hammer & dolly. The object is to remove some of the shrinking you’ve caused by welding, while keeping your panel in shape. Don’t stray too far from the weld to begin with. You’ll find you can get your shape back if you patiently work the weld area first, and then address any peripheral warpage. Remember, if your panel fits well to begin with, you should be able to make it fit when you’re finished, without resorting to drastic measures. Here is an excerpt from the directions that I send out with my shrinking disc. This may help a little with metal-finishing:
Dent repair and metal-finishing: To repair a dent, use a dolly to bump up the low spot from behind. Some larger dents are best worked from the perimeter in. Bumping with a dolly will bring the dent back near the original contour. This simple step is important throughout the repair, because, in addition to the inevitable small areas that need minor stretching later in the process, you will probably find low spots that just need bumping up. After bumping the dent up to its original contour, start working the metal off-dolly. This means pushing up with a dolly on low spots while hitting high spots with a hammer or slapper. This will start to get the panel smoother. Now start some medium-force on-dolly work. Usually, on-dolly work is stretching the metal between the hammer and dolly but, in this case, very little stretching is done, especially if you use a slapper instead of a hammer, as the force of the blow is spread more evenly. You are using multiple hits to planish (smooth) the area. Now check the shape of the panel. Use templates taken from the same spot on the other side of the car wherever possible. Use one up and down, and another front to back to see where the shape is too low or too high. Sometimes the whole area will still be too low and need more bumping and hammer-and-dolly work. Once you are satisfied that the general shape is right, you can start to pick up specific low spots by stretching on-dolly. Use a dolly that has a slightly higher crown than the panel being worked, and a hammer with a slight crown in it. This way there is a small contact area between the hammer and dolly, making it easier to stretch small areas up. You must push up fairly hard on the dolly. You should see small marks on the metal where it is stretched by the blows. Lightly file the area to show the highs and lows, then repeat the hammer-and-dolly steps, and file lightly again until you have the whole area smooth but a little too high. As an alternative to stretching up the low spots with a hammer and dolly, a tool called a bullseye pick [available from Ron Covell on my links page] can be modified to work very well. It is a little easier to use and may be easier on your arms if you have a lot of work to do. The tip must be ground down so that it is not so sharp, otherwise it will damage the panel
Welding Galvanized Steel with Flux Cored Arc Welding
12.15.11
Galvanizing has been used to protect iron and steel from rusting.Galvanizing is simply coating of zinc over steel. Also provides electrochemical protection of the steel, Since zinc is electrochemically more reactive than steel, it oxidizes to protect the steel near it. Welding of galvanized steel is done almost exactly the same way as welding of the bare steel of the same composition. The difference between welding galvanized steel and welding uncoated steel is a result of the low vaporization temperature of the zinc coating.
When zinc vapor mixes with the oxygen in the air, it reacts instantly to become zinc oxide. Zinc oxide is non-toxic and non carcinogenic. Zinc oxide that is inhaled is simply absorbed and eliminated by the body without complications or chronic effects. Current research on zinc oxide fumes is concentrated in establishing the mechanism by which zinc oxide causes "metal fume fever."
When using SMAW ("stick") welding, galvanized steel can be welded in the same manner as uncoated steel. When using MIG or flux cored welding, one may have to adjust the voltage slightly to control spatter, and one may have to clean the welding gun of spatter and zinc oxide deposits more frequently that when welding uncoated steel. The thicker the zinc coating, the more fumes are generated, and those fumes have to be able to escape easily into the atmosphere and not be forced through the liquid weld metal.
Fire Hazards When Welding and Plasma Cutting
12.14.11
Fire prevention and protection is the responsibility of welders and cutters. Approximately six percent of the fires in industrial plants are caused by cutting and welding which has been done primarily with portable equipment or in areas not specifically designated for such work.
During the welding and cutting operations, sparks and molten spatter are formal which sometimes fly considerable distances. Sparks have also fallen through cracks, pipe holes, or other small openings in floors and partitions, starting fires in other areas which temporarily may go unnoticed. For these reasons, welding or cutting should not be done near flammable materials unless every precaution is taken to prevent ignition.
Hot pieces of base metal may come in contact with combustible materials and start fires. Fires and explosions have also been caused when heat is transmitted through walls of containers to flammable atmospheres or to combustibles within containers. Anything that is combustible or flammable is susceptible to ignition by cutting and welding.When welding or cutting parts of vehicles, the oil pan, gasoline tank, and other parts of the vehicle are considered fire hazards and must be removed or effectively shielded from sparks, slag, and molten metal.
Whenever possible, flammable materials attached to or near equipment requiring welding, brazing, or cutting will be removed. If removal is not practical, a suitable shield of heat resistant material should be used to protect the flammable material. Fire extinguishing equipment, for any type of fire that may be encountered, must be present.
Welding Aluminum With A Stick Welder
12.13.11
Set the current on the machine. You will need a welder capable of at least 200 amps to successfully weld aluminum materials. Set the machine to between 190 and 210 amps, depending on the thickness of the material to weld. Unfortunately because of the deep penetration that stick welding aluminum creates, it is only recommended for quarter-inch and thicker material in most cases.
Watch the length of your arc. Generally, when stick welding aluminum, the arc length should be about the same as the diameter of the aluminum rod. Holding the rod too close to the aluminum decreases the voltage and compromises penetration. Holding the rod too far away increases the voltage but will cause porosity in the weld as well as lots of spatter. With a little practice, keeping the arc at a steady distance from the work becomes second nature.
Angle the rod at about 15 degrees against the aluminum being welded. If the rod is held straight up and down, it may not produce a clean arc, and the weld will be compromised. Holding it at 25 degrees or more will result in poor penetration and cause the weld to be weak. Drag the rod away from the weld rather than pushing into the weld as one might do with an MIG wire feed setup.
Develop a weld style and stick with it. Some people like to weld in a straight bee-line, which will produce a fine weld in most cases. Others like to make little "C" traveling arcs with the welding rod, which will create a weld that resembles a stack of dimes. Another technique is to zig-zag the rod back and forth across the gap, pausing for a second at each side before continuing diagonally over to the other side. All these styles work equally well, and it is purely a matter of taste which you choose for your own stick welding. Just remember to travel slowly to ensure a good puddle and nice penetration. Aluminum cools and dissipates heat very quickly, which is why it needs more amps. Therefore moving the rod as slowly as possible will keep the alloy heated well enough to weld.
Silent Generators
12.05.11
Both diesel and petrol generators provide power in similar ways. Diesel electrical generators are usually found in agricultural environments, on building sites and in factories and warehouses: in reality, anywhere there is a need for a portable and reliable source of energy. This can be because there is no mains power (as with building sites) or the mains power cannot be relied upon (agricultural areas and factories).
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When you are figuring out your generator requirements, it is important to choose the most efficient model. The size of the petrol generators is indicated by the output and speed provided by the manufacturer: generally speaking, a more powerful generator has a higher output and speed. Most generators fall between an output of 5KVA (kilovolt-ampere units) and 2500KVA. The lower KVA generators can be used in the home, whereas those with a higher KVA rating are more than ample for most industrial situations.
The efficiency of the model is the number one step: however, you will also have to calculate the load you need to supply. To do this, you simply have to calculate the power demand, either for the home or the business, during normal operating conditions. The amount of power that the generator can provide will indicate to you whether it is sufficient to meet the demands of your home or business: the amount of fuel in the tank only determines how long the generator will operate between refueling.It is always sensible to choose a generator that provides a slightly higher level of power than you absolutely need, thus reducing the chance of overloading.
Great tips to get a fine cut using a plasma cutter
12.01.11
Use new consumables. if you need a really good cut, use a brand new electrode and nozzle...or at least one that is barely used. You can not get a good cut when your plasma arc is shooting off to the side towards Aunt Nancy's house.
For thin metal, set the amperage low enough so that you can drag the tip against the metal. This will allow for the tightest cut with less heat and distortion.
Make sure your air pressure is right and that your air is dry. Plasma cutters are very finicky about the input pressure. They also hate moisture in the air. You need to buy a dryer if your shop air is not dry enough.
Some Advantages of Mig Welding
11.30.11
Some of the advantages of Mig welding are high quality welds can be produced much faster. Since a flux is not used, there is no chance for the entrapment of slag in the weld metal resulting in high quality welds. The gas shield protects the arc so that there is very little loss of alloying elements. Only minor weld spatter is produced. MIG welding is versatile and can be used with a wide variety of metals and alloys. The MIG process can be operated several ways, including semi and fully automatic.
Some of the disadvantages of Mig welding is that it cannot be used in the vertical or overhead welding positions because of the high heat input and the fluidity of the weld puddle. The equipment is complex.
MIG equipment consists of a welding gun, a power supply, a shielding gas supply, and a wire-drive system which pulls the wire electrode from a spool and pushes it through a welding gun. A source of cooling water may be required for the water cooled welding gun. There are also Mig rod ovens for proper storage of electrodes.
The majority of MIG welding applications require direct current, reverse polarity. This type of electrical connection yields a stable arc, helps to smooth the metal transfer, has relatively low spatter loss, and gives good weld bead characteristics. Direct current straight polarity (electrode negative) is seldom used, since the arc can become unstable and erratic even though the electrode-melting rate is higher.
Alternating current has found no commercial acceptance with MIG welding because the arc is extinguished during each half cycle as the current reduces to zero and it may not re-ignite if the cathode cools sufficiently.
Flux-Cored Arc Welding Techniques
11.29.11
The techniques used in flux-cored arc welding are much the same as those used in other welding methods—especially MIG welding. The electrode type, the flux type, the metal thickness, and the welding position will help determine which technique might work best on a certain project.
Backhand Technique
The backhand technique is often used with self-shielded flux-cored arc welding. This technique is achieved by passing the electrode along the welding site in the direction opposite that of welding.
When using the backhand technique, the handle of the welder is dragged like a stick welder. This technique works well when welding in the flat and horizontal positions. It may also be an option when welding in the 4G position to avoid being hit by spatter.
The backhand welding method creates a weld that is high and narrow—one that penetrates deeply. A disadvantage of using the backhand technique is that the weld puddle is a bit harder to see. As in stick welding, you need to keep an eye on the weld puddle size behind the crater.
Forehand Technique
The forehand welding technique is often used with gas-shielded flux-cored arc welding. The forehand process requires the electrode to be moved along the work site in the same direction as the welding.
The forehand method is often used when working with thinner metals. It may be the best method to use when welding in the vertical up position and for overhead fillet welds (4F). The forehand technique can also be used in the flat and horizontal positions.
Unlike the backhand method, the forehand welding technique makes it easy to see the weld puddle. As a result, it is also easier to see the weld joint and to keep from wandering off the joint.
With the forehand technique, it is important to try to keep the travel angle just right, so as to prevent excessive accumulation of spatter.
Arc Welding Techniques
11.28.11
Strike an arc moving the welding rod across the plate at a uniform speed and at an incline of about 20 degrees in the direction of travel. A right handed person usually welds from left to right. Steady your elbow against your body, the table, or the work. Use the free hand as needed to control the stinger. Run beads that consume the entire rod. Let the arc penetrate the base metal and deposit the filler metal (from the rod) into the joint, Continue to strike arcs and run beads across the joint making proper adjustments until you start and stop as desired, with no problems. No further adjustments should be needed. Burn the rod down to about 1 and 1/2" from the end. One welding rod usually produces a weld about 1" long.
When you stop there is a "crater." Chip the slag and re-strike the arc a little bit ahead of the crater and then run the bead. In time this method will produce uniform welds of high strength without trapping any slag in the bead that cause defects. At the end of a weld or when the rod is used up, pause slightly to fill the crater then pull the rod away. Chip the slag and inspect the weld.
Good welds are dependent on five techniques: correct amperage setting; correct arc length; correct rod selection and angle to the work; correct travel speed; and welding rods that have been stored and maintained properly.
When electrodes absorb moisture from the atmosphere, they must be dried in order to restore the ability to deposit quality welds. Electrodes with too much moisture cause unexplained cracking, poor operating characteristics, and porosity. If you've experienced these conditions it usually is due to your storage methods or re-drying procedures. All electrodes, even those outside of the "stick" category, must be stored and then dried to the right level to work well. Even a small amount of moisture in low hydrogen electrodes, for example, can lead to major weld problems such as internal porosity and weld cracking.
Too little amperage causes a weak arc that is hard to strike. Too much amperage causes a large crater, or a flat bead with excessive spatter. An arc that is too short will make the rod stick. Too long and large drops of melted metal will drip off the rod and it will tend to "blow' and spatter. A long arc also produces uneven bead with poor penetration.
Choosing which gas to use for Plasma Cutting
11.22.11
Many fabricators choose plasma systems with "dual-gas" or "multi-gas" capability. This means that a variety of plasma and shield gases can be used for various applications.
Multi-gas torches offer the most flexibility for shops that cut a variety of materials. Different gases are used, depending on material type and thickness, in order to achieve the best balance of cut quality, parts life, productivity, and overall cost of operation. Most plasma system manuals tend to overwhelm the operator with a confusing array of cut charts and gas choices. Often when you ask the operator why a particular gas is used for a cutting task a typical answer is: "My gas supplier told me to use this gas." The intent of this article is to provide a brief overview of the advantages and disadvantages of each gas and make "best case" recommendations for cutting the three most common materials: mild steel, stainless steel and aluminum.
Air is the most versatile plasma gas; it produces good cut quality and speed on mild steel, stainless, and aluminum. Air also lowers the cost of operation because it is not necessary to purchase gases. (For this reason air plasma systems are not popular with gas suppliers.) However air is not free. Shop air must be cleaned to remove contamination such as particulate, oil mist, and moisture. The best solution for air plasma systems is a good-sized, dedicated air compressor.
Safety Tips for Auto Darkening Helmets
11.21.11
The viewing lens — or filter — is a special piece of dark tinted glass, most often with a #10 shade and ultraviolet (UV) and infrared (IR) coatings.
When the welder is ready to begin welding, a quick nod or snap of the neck flips the helmet down before striking an arc. When finished, the welder reaches to pivot the helmet up and away from his face to view the work piece and to reposition for the next weld. Although inexpensive, standard helmets have several disadvantages:
It is difficult to keep the gun/torch in the correct position to begin welding after lowering the helmet in place, especially for beginners. When welding in restricted spaces, such as under cars or trailers, there isn't enough room to flip a helmet up and down.
The repetitive task of flipping up and down causes neck discomfort after a day of welding. And, finally, lifting and lowering a helmet is inefficient especially while doing a lot of tack welding. Auto-darkening welding helmets resolve all of these problems.
Instead of a standard piece of tinted glass, helmets with auto-darkening filters have an electronic filter lens and often are equipped with adjustable features to make welding easy.
Wearing the proper gear for welding
11.11.11
Any exposed skin is susceptible to the painful and damaging effects of ultraviolet and infrared rays. Further, sparks can catch in open pockets, pant cuffs or down a shirt that isn’t completely buttoned. These sparks can smolder unnoticed while the welder is “under the hood,” causing serious damage. Button shirt collars, cuffs and front pockets to prevent them from catching sparks and be sure to cover all exposed skin. Do not keep matches or butane lighters in your pockets. Avoid wearing cuffed pants because the cuffs also might catch sparks.
Neither shorts nor short-sleeved shirts belong in a welding cell. Even a quick tack weld requires the proper safety gear, including a helmet, gloves and appropriate clothing. Wear only flame-resistant clothing, such as denim pants and a shirt made from tightly woven material or a welding jacket. The excuse that welding jackets are too heavy, hot, restricting or cumbersome is quickly becoming a thing of the past. Makers of safety gear now produce lightweight clothing from flame-resistant cloth, pigskin leather and combinations of the two that offer better protection and increased ease of movement.
High-top leather shoes or boots provide the best foot protection. Pants legs should go over shoes. Do not wear tennis shoes or cloth shoes that can smolder, causing a burning sensation.
Fumes and smoke emitted during welding pose a health hazard. When welding in confined spaces, toxic fumes may accumulate, or shielding gases might replace breathable air. Use an exhaust hood to remove fumes from the area and ensure enough clean breathing air is available. Some materials specifically require respirators when welding, so consult the manufacturer's welding electrode data sheet, your welding engineer or an industrial safety specialist for proper procedures.
Choosing the correct Generator
11.10.11
If you are thinking small and only require a portable silent generator that can power a small motor home, then a 1 kilo watt (kW) model may be enough. If you need more juice to run heavier appliances, a 2 kW model may be just right. If you need one that can power an entire house or an entire business establishment, you may need to go for 5 to 7 kW machines that could supply a lot of electricity.
you will also need to check what the outlets available in the generators that you can plug in your electric appliances. There are, of course, outlets for both 120 and 240 volt appliances but you will need to ascertain what your generator is coming with because this can be different from region to region, And finally, you will need to decide on which fuel type you prefer in your generator. The most common are gasoline, propane and diesel.
If you wish to save on fuel costs, then you should go for a silent diesel generator as they are generally more efficient and economical and should outlast the other two because diesel is actually a light grade oil that helps protect the generator engine mechanisms from wear and tear. Gasoline and propane generators will probably require higher maintenance costs because of this.
Plasma cutting different types of metal
11.09.11
A lot happens in a plasma arc from its generation at the electrode surface to the workpiece. Among numerous other factors, the plasma forming gas and its surrounding shield material, be it gas or liquid, play a major role in the final cut quality.
A high-quality cut is characterized by a low bevel angle (ideally between 0 and 1 degree), absence of bottom dross, no top edge rounding, minimal heat-affected zone (HAZ), and a smooth cut face. The cut edge smoothness can be affected by the stability of the plasma arc column, due in part to the torch design, as well as the precision of the cutting table or robot. In addition, optimal cut quality requires the proper torch height to produce a minimal bevel angle.
All plasma cutting variations have an optimal cutting speed window that produces dross-free cuts. If the torch goes faster, the bevel angle increases, eventually leading to high-speed dross that sticks to the bottom of the cut, which can be difficult to grind off. If the torch moves too slowly, the process produces low-speed dross, which is thick, porous, and easier to remove. But the slow speed also puts more heat into the material than necessary, leading to a larger HAZ and top edge rounding.
Any rough or chemically contaminated cut edge can create problems for the welder. To ensure weld integrity, he may need to consider other procedures, such as grinding; alternative filler metal; or a change in travel speed. Extensive grinding could produce a surface ready for short-circuit gas metal arc welding, but without such grinding, the transfer mode can be problematic because it allows the weld pool liquid to freeze quickly and possibly trap contaminants, such as nitrogen. Welding processes that produce slower-freezing weld pools, such as submerged arc welding or flux-core arc welding, allow more contaminants to outgas.
Mig Welding Stainless Steel Pipes
11.08.11
Stainless steel pipe welds like this are typically fit up using a 1/8” gap +or- 1/32” and each pipe member is beveled to 37.5 degrees plus or minus 2.5 degrees. The sharp edge of the bevel is sometimes filed or ground to about 1/16” usually depending on welder preference
The inside of the pipe is usually purged with argon to prevent oxidation of the weld also known as sugaring or granulation. If the fit up is right and the technique is right, the root pass will look like it has been welded from the inside. It should look like a “wedding band” on the inside.
Longevity machines use IGBT technology that is also being implemented by other big companies that use circuitry to control the arc in such a way that the arc is smoother, there is less spatter, sidewall fusion is better, and sometimes purge gas can even be omitted.
Eliminating the purge gas from stainless steel pipe joints will make any contractor more competitive and productive because sometimes it takes an hour or more to purge long runs of pipe when joining long piping systems.
Since Argon is heavier than air, it is usually used for the purge gas for stainless steel pipe. All openings are sealed with tape and a hose is inserted with argon flowing. Argon fills the pipe and displaces oxygen.
Welding Aluminum Alloys
11.07.11
Aluminum and its alloys can be joined by more methods than any other metal, but aluminum has several chemical and physical properties that need to be understood when using the various joining processes.
The specific properties that affect welding are its oxide characteristics, its thermal, electrical, and nonmagnetic characteristics, lack of color change when heated, and wide range of mechanical properties and melting temperatures that result from alloying with other metals.
Oxide. Aluminum oxide melts at about 2050 oC which is much higher than the melting point of the base alloy. If the oxide is not removed or displaced, the result is incomplete fusion. In some joining processes, chlorides and fluorides are used in order to remove the oxide contain. Chlorides and fluorides must be removed after the joining operation to avoid a possible corrosion problem in service.
Advantages of Mig Welding
10.28.11
MIG welding can be used on all thicknesses of steels, on aluminum, nickel, and even on stainless steel, etc. However, it is most typically utilized in manufacturing and in commercial fabrication settings.
Advantages of MIG welding are:
High quality welds can be produced much faster
Since a flux is not used, there is no chance for the entrapment of slag in the weld metal resulting in high quality welds
The gas shield protects the arc so that there is very little loss of alloying elements. Only minor weld spatter is produced
MIG welding is versatile and can be used with a wide variety of metals and alloys
The MIG process can be operated several ways, including semi and fully automatic
Two Disadvantages are:
The MIG welding cannot be used in the vertical or overhead welding positions because of the high heat input and the fluidity of the weld puddle
The equipment is complex.
MIG equipment consists of a welding gun, a power supply, a shielding gas supply, and a wire-drive system which pulls the wire electrode from a spool and pushes it through a welding gun. A source of cooling water may be required for the water cooled welding gun. There are also Mig rod ovens for proper storage of electrodes.
Welding Sheet Metal
10.26.11
Restoring or building any car is a series of steps, each one building upon the other so that each step can only be as good as the one before it. While there are no unimportant steps, some are definitely more noticeable than others if they are done incorrectly. Every restoration that passes through MCR needs some sort of sheet metal work that involves welding in new pieces.
First off, never overlap seams, always butt weld. Second, never stitch weld, you'll warp the panels beyond repair. The proper way to do this is to do a series of tack welds that are quickly quenched, not by water, but with an air nozzle.
Whether you are replacing a body panel with a new aftermarket piece from Year One or a used part from a donor car, the process is the same. You start by cutting the panel oversize so there is enough overlap to hold it in place.
Use a small screwdriver and the tip of your finger to line things up before you place each tack weld. Now simply place a weld about every inch, alternating sides and quenching with compressed air, until you have the entire panel in place, pulling Clecos and extending the cut as you go.
Using Aluminum welding for repairs
10.25.11
There are a handful of Tig Welding supplies that you really need to get started. You definitely need some good Tig Welding gloves. Not garden gloves from Home Depot, Not big ASS Stick welding gloves that you have a hard time picking up a stick rod with....But Tig Welding gloves that are so soft you can pick up a dime. Gloves that almost sexually arouse you when you put em on. They really make a difference in being able to feed the filler rod.
When someone runs their aluminum boat prop into the lake bottom , usually it can be repaired by replacing the worn or chipped metal with weld metal. The problem is the any aluminum that has been in service like a boat prop or engine crankcase, soaks up some crap. Its like a sponge. Aluminum boat props always have some corrosion going on in the microscopic crevices of the metal and it seems to want to escape during the welding process. Sometimes, you dont notice it while you are welding and you think its all good until you blend off the weld.
More Mig Welding Tips
10.24.11
Remember that you never can be too safe when welding!
Be very careful with your eyes. Do not cut or weld without the appropriate eye protection. Make sure you have the proper shade when cutting and welding. Be sure to read and learn all welding safety procedures. Welding can be a fun, safe hobby as long as you educate yourself and use common sense.
Along with practice, practice, practice, remember safety, safety, safety!
You can MIG weld mild steel, stainless, and aluminum, although you will need a special adapter for aluminum.
MIG is great for welding motorcycle frames and race car frames. And although it keeps the heat-affected zone concentrated, remember to be careful with the amount of heat used.
Use nozzle dip or antispatter spray to keep your gun nozzle from getting clogged with spatter (molten welding droplets that solidify and stick to the inside of the nozzle, obstructing shielding gas flow).
Air Cooled VS Water Cooled
10.20.11
It's Easy For You To Convert Your Entry Level Air-Cooled TIG Welding Machine To The Benefits of A High-Performance, Cool-Running Water-Cooled TIG Torch!
A water-cooled TIG torch is smaller, more efficient, delivers more amperage and lets you weld longer at much higher amperages.
Water Cooled Torch Cons
o cooler /recirculation unit required and they are expensive
o more expensive than air cooled torches
o more complicated to hook up
o some maintenance is required on the coolant system
Air Cooled Torch Cons
o Larger than water cooled torches with the same amperage rating
o Get hotter in your hand
o Not available in high amperage ratings
Propane VS. Acetylene
10.19.11
*Maximum neutral flame temperature of acetelyne in oxygen is about 5720oF.
*Maximum neutral flame tempature of propane in oxygen is about 5112oF.
-The difference doesn't really matter as the real concern is for the thermal output ( BTUs ).
*BTU's of Acetylene is approximately 1470 btu's per cubic foot.
*BTU's of Propane is approximately 2498 btu's per cubic foot.
In the welding industry the vast majority of preheating is done with Oxygen / Propane . This is a fact . They don't do it just because it's cheaper but because the available heat from propane is much higher.Propane releases only a small proportion of heat in the inner flame cone ( less than 10% ), so most of the heat in the flame is in located in the outer cone . Acetylene releases almost 40% of its heat in the inner flame cone.
Just about all industrial plate cutting operations today not using Plasma Cutting Technology ( CNC tables ) are normally done with Oxygen / Propane or Propane derivatives. If you watch these tables cut, it will simply amaze you how quickly they can start a cut on 1" and over plate using the lowly Propane gas.
Different types of Techniques used for Tig Welding
10.18.11
Different types of Techniques used for Tig Welding
The different techniques of TIG welding mentioned below are used for different industrial applications. A brief account of three TIG welding techniques, the pulse-current, dabber, and hot wire is given below.
Dabber: This technique is used to increase the accuracy of welding. In this method, a cold filler wire is used for feeding, and it is dabbed or oscillated into the welding area. This method is used for welding nickel, titanium, tool steels and various alloys. Milling cutters, seals in jet engines, mower blades, and drill bits are the common applications where the dabber technique is used.
Pulsed-current: In the pulsed-current technique, the current used in welding alternates between two levels, i.e. the pulse and background current. The pulse-current denotes a higher current while the background current means a lower current. In the pulsed-current technique of welding, the weld area gets heated and the fusion takes places during the pulse-current or higher current period. During the period of lower or background current, the weld area solidifies due to cooling. Some of the advantages of using the pulsed-current method is that the amount of warpage or distortion in welding is reduced considerably. Weld speed and weld penetration increases, while the quality of welding is improved if this technique is used.
Hot Wire: The hot wire technique of welding is slightly different than the above mentioned techniques. In this method, filler metal to be added during welding is 'resistance heated'. The heating is done till the filler metal reaches its melting point. The deposition rate of the machine is increased because of prior heating of the filler metal. This technique is mostly used in 'hardfacing' operations.
Choosing A CNC Table
10.17.11
More and more shop owners are deciding that CNC plasma cutting tables are great additions to their shops. The computer-controlled robotic arm can guide the plasma torch over the surface of the work to create intricate and complex cutting patterns. With the ability to cut so precisely, the money-making possibilities are endless: create metal art for sale at trade shows and art galleries; create complex HVAC ductwork with ease; create a prototype of a concept part; create one-off or hard to find mechanical parts.
But buying a CNC machine is not as easy as running down to the hardware store and picking one up. You’ll want to consider a few questions to help make your buying decision easier. With careful research beforehand you can save yourself and your company considerable time and expense.
First and foremost, the number one thing to make sure of is that you're getting a high quality machine. CNC plasma cutting tables (no matter the manufacturer) are expensive. Do your homework beforehand and make sure you're getting the highest quality your budget will allow.
Different types of welding processes
10.14.11
SMAW - Shielded Metal Arc Welding or Stick Electrode
SMAW is an electric arc welding process in which heat for welding is generated by an electric arc between a covered metal electrode & the base metal. The electrode coating provides shielding. The welding equipment for this process is currently the most inexpensive of the methods described here. However, electrodes do create some inefficiency, such as stub loss & a slag coating, which must be removed.
GTAW - Gas Tungsten Arc Welding-Tig Welding
Tig Welding is easily performed on a variety of metals. It generally requires little or no post weld finishing. It is an electric welding process in which heat for welding is generated by an electric arc between the end of a non-consumable tungsten electrode & the base metal. Filler metal may be added, if necessary. An inert shielding gas supplies shielding for the arc. (Inert gas creates a protective atmosphere around the welding in process).
FCAW - Flux Cored Arc Welding-Mig Welding
Flux is contained within the electrode. It provides shielding, deoxidization & arc stabilization. Additional shielding may be added. A smoke suction nozzle around the gun or fume hood aids in reduction of smoke & fumes. Aufhauser flux cored stainless steel wire is formulated to provide all position welding & smooth, stable arc action.
GMAW - Gas Metal Arc Welding-Mig Welding
Gas metal arc welding is quick & easy on thin-gauge metal as well as heavy plate. It generally calls for little post weld cleanup. GMAW is an electric arc welding process where heat is produced by an arc between a continuously fed filler metal electrode & the base metal. Shielding is obtained from an externally supplied gas or gas mixture. The two most common types of GMAW are:
Short Circuit Transfer - The arc is broken or short circuited with each drop of metal & restarted. It is used on smaller, thinner gauges & produces a shallow weld.
Spray Transfer - Metal is transferred across the arc creating a continuous spray of fine droplets of metal. These droplets are projected down to the base metal.
Stick Welding Technique
10.13.11
Run a practice bead. Strike an arc moving the welding rod across the plate at a uniform speed and at an incline of about 20 degrees in the direction of travel. A right handed person usually welds from left to right. Steady your elbow against your body, the table, or the work. Use the free hand as needed to control the stinger. Run beads that consume the entire rod. Let the arc penetrate the base metal and deposit the filler metal (from the rod) into the joint.
Continue to strike arcs and run beads across the joint making proper adjustments until you start and stop as desired, with no problems. No further adjustments should be needed. Burn the rod down to about 1 and 1/2" from the end. One welding rod usually produces a weld about 1" long.
Mig Welding Tips
10.12.11
MIG welding unlike most other welding processes has one standard voltage type and polarity type. The voltage used is D/C direct current, much like the current in a car battery. Direct current flows in one direction, from the negative (-) to the positive (+).
The polarity used is also standard and that is D/C electrode (+) positive. This means that the handle is the positive side of the circuit, or it may be said, the electricity flows from the metal in to the welding handle.
The power source used for MIG welding is called a “constant voltage power supply”. In MIG welding the voltage is what is controlled and adjusted. When comparing MIG welding to Arc or TIG welding, MIG welding machines use voltage settings to set the machine. TIG and Arc welding machines use amperage to set the machine or a “constant amperage power supply”.
How to Set Different Transfer Types:
If you have never MIG welded it would help to know that there are no settings on a MIG welding machine offering a choice of transfer type. The ways a different type of transfer are set have two ingredients. The first is the voltage settings and the second is the type of gas used.
Most short circuit transfer welding is done with lower voltage and usually using Carbon Dioxide or a Carbon Dioxide gas mixture.
Globular and spray transfer use a higher voltage setting and commonly use Aragon gas. The Argon gas may contain a percentage of Carbon Dioxide, Helium, and or Oxygen.
Almost any metal may be MIG Welded
Mig Welding with Pulse on different types of metals
10.11.11
A modified spray transfer process that produces no spatter because the wire does not touch the weld puddle. Applications best suited for pulsed MIG are those currently using the short circuit transfer method for welding steel, 14 gauge (1.8 mm) and up. Consumables: contact tips, shielding gas, welding wire.
When manually welding most common carbon and low alloy steel applications, the purchase of costly pulsed MIG equipment, metal cored wires or three part gas mixes will not improve your weld quality, reduce your weld spatter, cut your weld costs, or help cut through the general MIG weld process confusion that prevails in most global weld shops. However the purchase will increase your weld equipment costs, add to your weld supplier's profits and generate more weld shop confusion.
ON STAINLESS APPLICATIONS. PULSED PROCESS BENEFITS ARE DERIVED FROM LOWER WELD CURRENT POTENTIAL LEADING TO DISTORTION REDUCTION. BE CONCERNED WHEN USING PULSED ON PARTS > 5 mm WITH THE WELD FUSION ATTAINED. FOR OPTIMUM WELD FUSION AND BEST ARC STABILITY ON HIGH SPEED WELDS USE SPRAY OR FOR BEST WELD QUALITY WITH THE LOWEST WELD DISTORTION CONSIDER TIP TIG.
Welding Sheet Metal with GMAW or GTAW
10.06.11
For welding with solid wires, use electrode positive or "reverse" polarity.While EP directs more heat into the base metal than electrode negative (EN or "straight" polarity)
If you've been using flux cored wire, be sure to change your machine's polarity from EN to EP.Smaller electrodes carry less heat and enable you to better focus the arc in a smaller area. For steel and stainless steel applications, keep the tungsten pointed, and be sure to grind parallel with the length. Clean all metals before welding, but especially aluminum. Remove oil and dirt with a degreaser/solvent. Just prior to welding, remove oxide with a stainless steel wire brush, grinder or chemical oxide cleaner. When exposed to air, an oxide layer forms on aluminum (aluminum oxide melts at a temperature 2,000 degrees higher than plain aluminum)
Direct the arc at the middle of the weld puddle. Normally, you would keep the arc on the leading edge, where the weld puddle is thinnest, to drive the arc into the work for more penetration. Staying back enables the puddle to insulate the base metal from the arc's full force. To prevent burn-through and warping, do not whip or weave the torch, as the more time you keep the arc in an area, the hotter it becomes.
Always travel in a straight line and use the fastest travel speed possible that maintains a good bead profile. Unevenly distributed heat causes distortion and warping, which in turn wreaks havoc on parts that theoretically fit together. To minimize warping, distribute the heat as evenly as possible. You can accomplish this by using a skip welding technique. If the metal starts to warp or pull to one side, solve this by: increasing the distance skipped between welds; welding at the beginning, middle and end of the piece, then repeating the sequence; or welding on alternate sides of the joint.
How to clean metal for welding
10.05.11
Check the metal before welding it. If the metal has a coating, which could possibly be a thin layer of metal, you must remove it. You can use a grinder to prepare the surface of the metal for welding.
lean the metal of any rust when you are preparing metal for welding. Metal on a car can be rusty, and before welding anything onto it, you'll need to take off any rust spots with a grinder or steel wool.
Try different techniques for cleaning metal as you prepare it for welding. Straight or flat grinders work well, but for metal of different shapes, you might want to use an angle grinder.
Take off any bad welds with a grinder when you are preparing metal fir welding. Removing a bad weld and starting over is often better than trying to make a bad weld better. Starting fresh means that you can now create a fresh, clean weld that will be nice and strong.
Use a grinder to clean the edges of the metal when you are preparing to weld metal together. By having clean edges, you can ensure that the weld will be solid and hold well.
Be sure to wear your safety glasses when you are preparing metal for welding
Mig Welding Techniques
10.04.11
Drag the welder close to the area you’re welding – enough so that you can reach over and touch the adjustment knobs while welding. Get the welder’s settings close to your liking. Then, while welding on a piece of scrap, slowly turn the wire speed knob up or down until you get your sharp “Frying Bacon” sound along with a nice looking bead.
If the weld is very tall, rough, or choppy, then the penetration may be insufficient. This is referred to as being TOO COLD!! If the weld is close to flat or slightly rounded, this is an indication that you’re getting the penetration you want. You don’t want the weld to be “Under Cut” which means below flat or cutting out the material.
A large chamfer on the material. An equal reveal on the material. A higher setting on the welder — especially for thicker material. A slower place — allowing more heat and more weld material to the joint — and a bigger “C”or “e” formation.
Don’t stitch weld because you usually don’t get the penetration you want — unless you are using a thinner material and wire such as sheet metal welding. I don’t push from right to left because it’s harder to get penetration. For that reason the weld is being pushed away from the molten puddle unlike the pulling technique where your wire is pushing back into the molten puddle. Also, the weld is a lot harder to control to make the weld look appealing.
Inverter Plasma Cutters
10.03.11
Analog plasma cutters, typically requiring more than 2 kilowatts, use a heavy mains-frequency transformer. Inverter plasma cutters rectify the mains supply to DC, which is fed into a high-frequency transistor inverter between 10 kHz to about 200 kHz. Higher switching frequencies give greater efficiencies in the transformer, allowing its size and weight to be reduced.
The transistors used were initially MOSFETs, but are now increasingly using IGBTs. With paralleled MOSFETs, if one of the transistors activates prematurely it can lead to a cascading failure of one quarter of the inverter. A later invention, IGBTs, are not as subject to this failure mode. IGBTs can be generally found in high current machines where it is not possible to parallel sufficient MOSFET transistors.
The switch mode topology is referred to as a dual transistor off-line forward converter. Although lighter and more powerful, some inverter plasma cutters, especially those without power factor correction, cannot be run from a generator (that means manufacturer of the inverter unit forbids doing so; it is only valid for small, light portable generators). However newer models have internal circuitry that allow units without power factor correction to run on light power generators.
Tig Welding Tungstens
09.30.11
Tungsten has the hardness and high-temperature resistance that make it ideal for carrying the welding current to the arc. Here’s what you need to know to gain top TIG welding performance.
Like any other welding process, TIG welding relies on the right equipment to get the job done properly, and from the power source to the TIG torch and cables, each component plays a critical role. But at the core of the TIG welding process is something unique: the tungsten electrode. This non-consumable metallic element has the highest melting point of any metal (3,410 degrees Celsius), making its hardness and high-temperature resistance the ideal option for carrying the welding current to the arc.
Choosing a specific type of tungsten for your TIG welding application doesn’t have to be difficult, but it depends on you having a little know-how. To begin, tungsten electrodes come in a variety of diameters — typically ranging from 0.040- to 5/32-inch — and they are available in industry-standard lengths of seven inches. Custom lengths are available, too, but they tend to cost more. The electrodes are composed either of pure tungsten or a hybrid of tungsten and other rare earth elements and oxides (all discussed below.) To eliminate confusion between the various types, each electrode is color-coded, with the color appearing at the tip of each electrode.
Aluminum Welding Techniques
09.29.11
Base-metal preparation: To weld aluminum, operators must take care to clean the base material and remove any aluminum oxide and hydrocarbon contamination from oils or cutting solvents.
Preheating: Preheating the aluminum workpiece can help avoid weld cracking.
The push technique: With aluminum, pushing the gun away from the weld puddle rather than pulling it will result in better cleaning action, reduced weld contamination, and improved shielding-gas coverage.
Travel speed: Aluminum welding needs to be performed "hot and fast."
Shielding Gas: Argon, due to its good cleaning action and penetration profile, is the most common shielding gas used when welding aluminum.
Welding wire: Select an aluminum filler wire that has a melting temperature similar to the base material.
Convex-shaped welds: In aluminum welding, crater cracking causes most failures.
Power-source selection: When selecting a power source for GMAW of aluminum, first consider the method of transfer -spray-arc or pulse.
Wire feeder: The preferred method for feeding soft aluminum wire long distances is the push-pull method, which employs an enclosed wire-feed cabinet to protect the wire from the environment.
Welding guns: Use a separate gun liner for welding aluminum.
Constant-current (cc) and constant-voltage (cv) machines can be used for spray-arc welding. Spray-arc takes a tiny stream of molten metal and sprays it across the arc from the electrode wire to the base material.
In some shops, welders use the same wire feeders to deliver steel and aluminum wire. In this case, the use of plastic or Teflon liners will help ensure smooth, consistent aluminum-wire feeding.
Use drive rolls designed for aluminum. Set drive-roll tension to deliver an even wire-feed rate. Excessive tension will deform the wire and cause rough and erratic feeding; too-little tension results in uneven feeding. Both conditions can lead to an unstable arc and weld porosity.
Change liners often to minimize the potential for the abrasive aluminum oxide to cause wire-feeding problems.
Use a contact tip approximately 0.015 inch larger than the diameter of the filler metal being used - as the tip heats, it will expand into an oval shape and possibly restrict wire feeding.
Stick Welding electrodes used for field repair
09.27.11
6010 Electrode: Electrode only suitable with DC power sources. It delivers deep penetration and has the ability to dig through rust, oil, paint and dirt. This electrode features an extremely tight arc, which can make it difficult for inexperienced welders. Excellent for penetration on joints with a tight fit-up.
6011 Electrode: Electrode with a soft arc and minimal spatter, moderate penetration and easily removable slag. Suitable with AC or DC power sources, this electrode is better served on newer and clean materials, thinner materials and wide root openings.
7018 Electrode: Electrode with a thick flux and high iron powder content, which makes it one of the easiest electrodes to use. These electrodes produce a smooth, quiet arc with minimal spatter and medium arc penetration. Produces strong welds with high impact properties (even in cold weather) and can be used on carbon steel, high-carbon, low-alloy and high-strength steel base metals. Suitable with AC and DC power sources.
7024 Electrode: Electrode mostly used For flat or horizontal welding with an AC or DC power source, this electrode contains a high iron powder content that helps increase deposition rates. Performs well on steel plate that is at least ¼-in. thick and can be used on metals that measure over ½ in.
Stick Welding Tips
09.26.11
Choose the right electrode:
Many welders are not sure of the type and size of the electrode that should be used in stick welding. The size of the electrode you choose should match the situation you are welding within and the kinds and thickness of metals.
Polarity matters:
If you purchase an A/C only welding equipment, then you need to get stick welding rods that are specifically created to weld Aluminum. Bear in mind that not all stick welding rods are created the same. 6011, 6013, and 7018, for instance, will weld on A/C, but 6010 wont.
Know your arc length:
For a successful stick welding job, you need to use an arc length that is the same distance from the metal as the thickness of your electrode. For example, if you own an electrode that is ½ inch thick, then have your arc ½ inch thick as well. Don’t forget that as you use the stick electrode, you will need to move it closer to the metal.
Why Plasma Cutting is better than Laser Cutting
09.22.11
Plasma (arc) cutting was developed in the 1950s for cutting of metals that could not be flame cut, such as stainless steel, aluminum and copper. The plasma arc cutting process uses electrically conductive gas to transfer energy from an electrical power source through a plasma cutting torch to the material being cut. The plasma gases include argon, hydrogen, nitrogen and mixtures, plus air and oxygen.
Normally, a plasma arc cutting system has a power supply, an arc starting circuit, and a torch. The power source and arc starter circuit are connected to the cutting torch through leads and cables that supply proper gas flow, electrical current flow, and high frequency to the torch to start and maintain the process. The arc and the plasma stream are focused by a very narrow nozzle orifice
The temperature of the plasma arc melts the metal and pierces through the workpiece while the high velocity gas flow removes the molten material from the bottom of the cut, or the kerf. In addition to high energy radiation (Ultraviolet and visible) generated by plasma arc cutting, the intense heat of the arc creates substantial quantities of fumes and smoke from vaporizing metal in the kerf..
Welding with spool gun
09.21.11
Connect the welding cable from the spool gun to the positive terminal in the welding machine.
Straighten a length of aluminum wire from the spool and insert it through the gun, from the rear of the spool housing through the guides and out the tip. Close the tension arm over the wire, replace the cover over the tension arm and then screw on a contact tip that matches the gauge of aluminum wire you are using, followed by the welded nozzle tip.
Clean the surfaces of the aluminum you wish to weld using a stainless steel wire brush and clamp them together in the orientation you would like to weld them permanently. Welding aluminum sheet of less than 14 gauge will most likely result in a burn through, so stick to thicker gauges.
Place the tip of the welding nozzle about 3/4 inch away from the surface of the aluminum at an angle of about 70 degrees. Then push the trigger and lay down a bead of weld. It is best practice with aluminum welding to push your weld rather than to pull it. There should be a hissing sound rather than the typical "bacon frying" sound of steel welding. If you are having problems with spattering of aluminum, or excessive smoke, adjust the voltage output on your welder until you achieve satisfactory beads.
Different Types Of Welding Electrodes
09.20.11
There are many types of welding electrodes. Welding electrodes are metal wires with baked on chemical coatings. The rod is used to sustain the welding arc and to provide the filler metal required for the joint to be welded. The coating protects the metal from damage, stabilizes the arc, and improves the weld. The diameter of the wire, less the coating, determines the size of the welding rod. This is expressed in fractions of an inch such as 3/32", 1/8", or 1/16". The smaller the diameter means it requires less current and it deposits a smaller amount of filler metal.
the welding process and machine, and other conditions determines the type of welding electrode used. For example, low carbon or "mild steel" requires a mild steel welding rod. Welding cast iron, aluminum or brass requires different welding rods and equipment.
The flux coating on the electrodes determines how it will act during the actual welding process. Some of the coating burns and the burnt flux forms smoke and acts as a shield around the welding "pool," to protect it from that air around it. Part of the flux melts and mixes with the wire and then floats the impurities to the surface. These impurities are known as "slag." A finished weld would be brittle and weak if not for the flux. When the welded joint is cooled, the slag can be removed. A chipping hammer and wire brush are used to clean and examine the weld.
The metal-arc welding electrodes may be grouped as bare electrodes, light coated electrodes, and shielded arc or heavy coated electrodes. The type used depends on the specific properties required that include: corrosion resistance, ductility, high tensile strength, the type of base metal to be welded; and the position of the weld that is flat, horizontal, vertical, or overhead.
Instructions on how to use your generator correctly
09.19.11
Gasoline-powered Generators can provide electrical power for household needs in the wake of a prolonged power outage, but they have their dangers if used improperly. Follow these tips to ensure the safe use of your generator. You shouldn’t use a generator indoors even if you open the windows and doors—an unlikely action indeed in hurricane conditions. Generators should never be used inside, including areas such as garages, crawlspaces, and basements. They should be placed outdoors and should be kept far away from doors and vents. Generators can quickly produce high levels of the poisonous gas carbon monoxide if not used in a ventilated area. Set up a canopy or other cover over the generator to prevent moisture from gathering. Make sure your hands are dry to avoid electrocution while using the generator.Heavy duty extension cords rated for outdoor use should be used for the generator. The wattage for each cord should exceed the total wattage of all appliances connected to it. Cords should have three prongs and not be pinched or torn. Generators should never be plugged into an outlet to power a house’s electrical grid. This creates “backfeeding,” or the transfer of electrical power into utility lines connected to your home, and this poses a risk to utility workers and neighbors on the same transformer. Backfeeding will also bypass some circuitry safeguards. Consult a qualified electrician if you wish to incorporate your generator into your home electrical system.
LONGEVITY Auto Darkening Welding Helmet
09.15.11
spending more on a Welding helmet will increase comfort, improve your welding ability, result in higher quality welds and ensure your safety. Unfortunately, selecting a helmet can be confusing if you're not familiar with the latest auto-darkening lens technology and national safety standards. Instead of a standard piece of tinted glass, Welding Helmets with auto-darkening filters have an electronic filter lens and often are equipped with adjustable features to make welding easy. The auto-darkening filter lens, or ADF, is a special liquid crystal display (LCD) that is similar in design to the technology used to display numbers on a digital alarm clock.Most filter cartridges are powered by a combination of battery and solar power.Several light sensors are mounted near the lens to detect the welding arc. When the lens is not activated, an auto-darkening LCD filter usually has a #3 or #4 shade, which is relatively easy to see through, similar to sunglasses. This makes arc starts easier because the welder can see the position of his MIG gun, TIG torch or stick electrode relative to the material he is welding.Once an arc is initiated, sensors on the helmet darken the lens to a shade #9 to #13, depending on the settings, hundreds of times faster than you can blink an eye.
Information On Tig Welding
09.14.11
Alternating Current (AC):
In Alternating Current (AC) polarity is inverted at every cycle. The frequency is 50 hertz or cycles per second in Europe and 60 Hz in the USA. In the standard transformer power supply the heat of the arc, because of alternant polarity, is evenly distributed between electrode and workpiece. The results of penetration depth and weld width are somewhat intermediate between DCEP and DCEN.
Pulsed DC:
Advances in electronic controls of power supplies permitted to introduce new wave forms, generally with electrode negative, characterized by current pulsed between a low maintenance or background value, that keeps the arc but allows the weld to cool somewhat, and a high peak value capable of melting metal in a controlled way while ensuring the required penetration.
Polarity:
The Tungsten Electrode in Gas Tungsten Arc Welding (GTAW or Tig) can make contact with a Direct Current (DC) power supply either at the positive (+) or at the negative (-) terminal. In the first case the connection is for DCEP (electrode positive) or reverse polarity. In the second one for DCEN (electrode negative) or straight polarity.
Welding Supplies and Accessories
09.13.11
Welding supplies for different kinds of welding such as gas welding, sonic welding, laser welding, arc welding, aluminum welding, MIG Welding, TIG Welding as well as others can easily be found on our LONGEVITY website to make the shopping experience convenient and more affordable. Protective and safety equipment: Safety equipment is essential when welding. Welders must at all times wear a shield which will protect their eyes and face from spatter from the molten metal and from the harmful electric rays. The face shield should have an adjustable headband to ensure the fit of the shield. Leather gloves, sleeves, and an apron should also be worn while welding. A leather jacket or bib may also be necessary depending on the position in which you are welding. A welding rod oven is necessary to place the welding rod containers once they are opened. Welding rod ovens will come tailored to your needs. Cutting/burning: Portable oxy/Acetylene burning outfits are often used. These outfits are on wheels and can be moved from one area to another and include the oxygen and acetylene cylinder, cutting torch, hoses, gauges, regulators and attached valves. Machine accessories: The electric current from the welding machine to the work and back to the welder require two cables of copper wire that are covered with a tough insulation. A lightweight "whip" and electrode holder are also necessary. When choosing a whip holder, you want the device to be light, yet sturdy and well insulated. To attach the ground cable to the welding table a ground clamp is required. Cable lugs are also required to attach the cable to the machine.
Welding Generators
09.12.11
Welding Generators can power a wide variety of equipment, including: sump pumps, milkers, high-pressure washers, electrical chain saws, flood lights, refrigerators or freezers, wet/dry vacs, televisions, radios, VCRs and microwaves. When buying a welding generator, you should confirm that the model you want has sufficient wattage. An electric generator is a device that converts mechanical energy obtained from an external source into electrical energy as the output. It is important to understand that a generator does not actually ‘create’ electrical energy. Instead, it uses the mechanical energy supplied to it to force the movement of electric charges present in the wire of its windings through an external electric circuit. This flow of electric charges constitutes the output electric current supplied by the generator. This mechanism can be understood by considering the generator to be analogous to a water pump, which causes the flow of water but does not actually ‘create’ the water flowing through it. The modern-day generator works on the principle of electromagnetic induction discovered by Michael Faraday in 1831-32. Faraday discovered that the above flow of electric charges could be induced by moving an electrical conductor, such as a wire that contains electric charges, in a magnetic field. This movement creates a voltage difference between the two ends of the wire or electrical conductor, which in turn causes the electric charges to flow, thus generating electric current.
Plasma Cutting
09.08.11
Plasma Cutting is a process that is used to cut steel and other metals of different thicknesses (or sometimes other materials) using a plasma torch. In this process, an inert gas (in some units, compressed air) is blown at high speed out of a nozzle; at the same time an electrical arc is formed through that gas from the nozzle to the surface being cut, turning some of that gas to plasma. The plasma is sufficiently hot to melt the metal being cut and moves sufficiently fast to blow molten metal away from the cut. The HF Contact type uses a high-frequency, high-voltage spark to ionise the air through the torch head and initiate an arc. These require the torch to be in contact with the job material when starting, and so are not suitable for applications involving computer numerical controlled (CNC) cutting. The Pilot Arc type uses a two cycle approach to producing plasma, avoiding the need for initial contact. First, a high-voltage, low current circuit is used to initialize a very small high-intensity spark within the torch body, thereby generating a small pocket of plasma gas. This is referred to as the pilot arc. The pilot arc has a return electrical path built into the torch head. The pilot arc will maintain itself until it is brought into proximity of the workpiece where it ignites the main plasma cutting arc. Plasma arcs are extremely hot and are in the range of 25,000 °C (45,000 °F).[1]
Guide To Wiring 220v
09.07.11
The Black wire carries 110v, The Red wire carries 110v (you can also use white wire or wire of any color, but mark it RED with electrical tape for your own convenience), The Green wire acts as ground or common.
Connect the RED, BLACK and GREEN wires in the main panel to the 3 prong receptacle. Extend the wire to the location you want the outlet.
Wiring a 220v Out let if you have 3 wires in the main panel:
Connect green wire to green, black to black , red to red and white to white. Connect the other ends of the wires accordingly to the 3 prong receptacle. If there is no GREEN in the receptacle, connect the wire to any of the mounting screw between the receptacle and the plastic box.
Use a voltmeter to test the voltage at the receptacle once the wiring is complete. There could be some variation say ± 5v to 10v, but this can be considered normal.
Wiring a 220v outlet or receptacle can be easy if you have prior experience in home wiring. However, if you have nor prior experience, then do not do it yourself; get help from a professional. Some of the codes and rules mentioned here may differ in different countries but the basic principle of home wiring is more or less the same around the world.
Removing Heat Tint After The Weld on Stainless Steel
09.06.11
If the intended application relies on the heat or oxidation resistance of the stainless steel, then removal of heat tint is not important, as, depending on the service temperature, oxidation heat tinting will occur and blend into any localised weld tinting.
As heat tint colours are formed on stainless steels chromium is drawn from below the surface of the metal to form a chromium rich oxide surface layer. This leaves the metal just below the surface with a lower chromium level.
In cases where the application involves 'aqueous' ie a low temperature corrosion hazard environment, the local reduction in sub-surface chromium can affect the corrosion resistance of the steel.
Although some sources suggest that the removal of heat tint is not always essential, it is vitally important that weld heat tint is removed so that the full corrosion resistance of the finished product is restored after welding. This will help avoid unnecessary service corrosion problems in fabrication weld areas.
Things to know about Mig Welding!!!
09.02.11
Drag the welder close to the area you’re Welding – enough so that you can reach over and touch the adjustment knobs while welding. Get the welder’s settings close to your liking. Then, while welding on a piece of scrap, slowly turn the wire speed knob up or down until you get your sharp “Frying Bacon” sound along with a nice looking bead. If the weld is very tall, rough, or choppy, then the penetration may be insufficient. This is referred to as being TOO COLD!! If the weld is close to flat or slightly rounded, this is an indication that you’re getting the penetration you want. Another way to insure that you have good penetration is: -A large chamfer on the material. -An equal reveal on the material. -A higher setting on the welder — especially for thicker material. -A slower place — allowing more heat and more weld material to the joint — and a bigger “C”or “e” formation
Arc Welding With Pulse
09.01.11
Pulsed arc welding is a welding process that involves a drop being formed from the background current pulsing and heating the filler wire. This drop is moved into the weld pool, producing a deeper penetrating weld. Well-suited for welding thinner materials, pulse arc welding creates a better root fusion than dip transfer or short circuiting modes. It not only has better penetration, but pulse arc welding uses less heat input. During each pulse, it is possible for more than one drop to move across the arc. Power supplies can change the pulse rate, current levels and pulse width independently, allowing for a wider range of weld options. In this kind of arc welding, pulse rates can range from 1 to 100 pulses per second, but there is some equipment available to allow for the rate to reach up to 1000 pulses per second. Pulse arc welding also has a wider power range to choose from. Pulse arc welding can also be referred to as Pulsed Spray Welding. It can be used during Metal Inert Gas (MIG) welding (MIG) and Tungsten Inert Gas (TIG) welding. MIG Welding, which is commonly called Gas Metal Arc Welding (GMAW), uses the pulse to project the droplets across the arc while using an inert gas to protect the weld from contaminants. TIG Welding, which also uses inert gas, utilizes the pulse to produce a high current with deeper penetration without excessive melting. This is especially beneficial for autogenous welds, which does not use a filler wire, on fixed tubing. The background current is what keeps the arc consistent between pulses. Using pulse arc welding can reduce the welding speed by 20 to 40%.
Cutting Techniques for Stainless Steel
08.30.11
Stainless steel can be cut and profiled in the same way and using the same type of equipment as for most other steels. Some differences in technique apply and these are explained below. The information in this article is specifically directed towards austenitic stainless steels, the most frequently used family of stainless steels. Austenitic stainless steels exhibit strong work hardening characteristics which affect many of the forming techniques. Machinery capability levels need to be increased (or existing capability levels down-rated) compared with carbon steels. A higher rigidity of tools and machinery is necessary for working stainless steel. All fabrication processes should be carried out in a clean, and if possible, a dedicated environment. The first operation undertaken in the fabrication workshop is that of cutting bulk materials into appropriate work pieces. This is readily achieved using existing machinery although in some cases the use of a specialist subcontract facility will be to advantage. Plasma Cutting This process is usually employed to produce shapes from plate material. A clean cut edge and minimum distortion are provided, but it should be noted that a slight taper is provided to the cut edge and due allowance should be made in the design and finishing of the component.
Stick Welding Stainless Steel
08.29.11
Place the two pieces of stainless steel flat on the welding table, with the sides that need to be welded resting 1/16 inch apart. Secure the pieces of stainless steel by clamping them to the welding table with self-locking clamps. Turn on the ARC welder and adjust the amperage for the size thickness and type of stainless steel welding electrode you are going to use to weld the stainless steel.
Put on your safety glasses, welding helmet and heavy leather welding gloves. Clamp a stainless steel welding electrode in the stinger of the ARC welder and connect the ARC welder's ground clamp to the welding table. Align the welding electrode with the joint between the two pieces of stainless steel and lower your welding helmet. Strike and lift the welding electrode on the stainless steel joint to start the ARC between the stainless steel pieces and the welding electrode.
Work the electrode over and down 1/8 inch, then back over the weld joint to weld the two pieces of stainless steel together. Remove your welding helmet and tap the weld with the chipping hammer to remove the slag from the stainless steel weld. Allow the weld joint to cool thoroughly before you handle the welded stainless steel--the weld joint will be hot and can cause severe burns.
Tig Welding Tips
08.26.11
TIG Welding Techniques The different techniques of TIG welding mentioned below are used for different industrial applications. Dabber: This technique is used to increase the accuracy of welding. In this method, a cold filler wire is used for feeding, and it is dabbed or oscillated into the welding area. This method is used for welding nickel, titanium, tool steels and various alloys. Milling cutters, seals in jet engines, mower blades, and drill bits are the common applications where the dabber technique is used. Pulsed-Current: In the pulsed-current technique, the current used in welding alternates between two levels, i.e. the pulse and background current. The pulse-current denotes a higher current while the background current means a lower current. In the pulsed-current technique of welding, the weld area gets heated and the fusion takes places during the pulse-current or higher current period. During the period of lower or background current, the weld area solidifies due to cooling. Some of the advantages of using the pulsed-current method is that the amount of warpage or distortion in welding is reduced considerably. Weld speed and weld penetration increases, while the quality of welding is improved if this technique is used. Hot Wire: The hot wire technique of welding is slightly different than the above mentioned techniques. In this method, filler metal to be added during welding is 'resistance heated'. The heating is done till the filler metal reaches its melting point. The deposition rate of the machine is increased because of prior heating of the filler metal. This technique is mostly used in 'hardfacing' operations.
New Welding Carts In Stock
08.25.11
Product Description
This heavy duty MIG welding cart features: * 3 Shelves for easy access to supplies * 18" x 10.5" top deck * Holds 9 1/2" diameter tank * Industrial powder coating resists chips and rust * Built in cylinder rack and storage tray * Heavy duty casters; 2 fixed and two swivel * Cart measures 28" L x 12" W x 28" H * 100 lb. weight capacity.
The LONGEVITY Welding Cart is very durable and capable of holding welding unit up to and over 100 lbs, it's a heavy duty cart and very easy to move around your shop,warehouse, etc...
Higher Density Gives You Better Plasma Cutting
08.24.11
The goal in plasma cutting, like in laser cutting, is to attain the highest energy density possible to efficiently penetrate the plate. Common to all plasma processes, constriction and stabilization are achieved by a small nozzle diameter in combination with the swirling motion of the plasma-forming gas. Depending on the process variation, further constriction can be achieved using water as a shielding material. Other mechanisms could be used to constrict and stabilize the arc, such as materials with high heat conductivity for the nozzle to evacuate the heat radiated by the constricted arc, or even intense magnetic fields. Currently, however, the cost of such systems would offset any gain in cut quality and speed.
For mild steel use oxygen plasma and air shield for the best cut quality, lowest dross levels, minimal rework, excellent weldability and highest cutting speed/productivity.
For best cut quality on stainless and aluminum under ½" use nitrogen plasma and air secondary for a good balance of cut quality and affordability. For a slightly better and faster cut, use CO2 as the secondary. If your system allows, water shield will provide the best edge quality.
For best cut quality on thick stainless and aluminum use Argon-Hydrogen with Nitrogen secondary. WARNING! Your system must be equipped for safe operation with argon hydrogen gas. For most economical cutting, clean dry shop air is the best choice for mild steel, stainless, and aluminum.
Silent Diesel Fueled Generators
08.23.11
A portable diesel generator is reliable – with a full tank, it can run for a maximum of 14 hours before it requires refueling. Industrial surveys cite some water-cooled diesel-run portable power generator engines that can produce 1800 rotations per minute (rpm) and run for 12,000 to 30,000 hours based on their engines’ power and capacity before actually requiring any maintenance. There are also portable power generators of the diesel variety that can supply you with anywhere from one to 10 kilovolt-amperes (kVA).
Portable diesel generators come in low noise models – since diesel engines are smaller and have an equally smaller number of individual parts, they make less noise compared to other gas engines. This is especially true for water-cooled engines, whose reduced noise makes it a good silent generator to have around. Adding a noise muffler can lower the noise pollution potential further (Read related article on the Buffalo GENSD7 silent diesel generator).
Portable diesel generators are cost efficient – when taken on a per kilowatt unit cost, a portable diesel generator costs 30% to 40% less compared to other portable power generators that run on gas. And even when left unused in the genset’s tank, diesel does not evaporate as easily as other fuels, making a portable diesel generator more cost efficient. One other advantage of diesel engines is that they can run on alternative fuels, such as biomass.
How CNC works
08.18.11
CNC stands for Computer Numerical Control and has been around since the early 1970's. Prior to this, it was called NC, for Numerical Control. In the early 1970's computers were introduced to these controls. CNC has touched almost every form of manufacturing process in one way or another. If you'll be working in manufacturing, it's likely that you'll be dealing with CNC on a regular basis.
everything that an operator would be required to do with conventional machine tools is programmable with CNC machines. Once the machine is setup and running, a CNC machine is quite simple to keep running. In fact CNC operators tend to get quite bored during lengthy production runs because there is so little to do. With some CNC machines, even the workpiece loading process has been automated. (We don't mean to over-simplify here. CNC operators are commonly required to do other things related to the CNC operation like measuring workpieces.
The CNC control will interpret a CNC program and activate the series of commands in sequential order. As it reads the program, the CNC control will activate the appropriate machine functions, cause axis motion, and in general, follow the instructions given in the program.
Stick Welding Tips
08.17.11
Stick welding is one of the most basic forms of welding being used today. This method of welding is usually one of the first types that welding students learn when starting out. It is a method that is commonly used on iron, boilers or in ship building. When learning stick welding, you will become aware of the importance of being able to weld in all types of positions, such as horizontal and flat, vertical or overhead. The ability to adapt to a welding situation is important when learning how to stick weld.
Choosing the right electrode – Having the correct size electrode for the job at hand is very important. The size of the electrode depends on the welding situation you are presented with. If you are welding vertically you will need an electrode that was specifically designed to be used in that situation. Knowing which electrode will best suit a situation is something that every stick welder should know.
Using a weld shelf – If your job requires that you weld in a horizontal or vertical position you may want to utilize a weld shelf. This will provide the electrode something to follow to lessen the amount of electrode lost due to gravity.
Don’t undercut – Undercutting may occur if you do not have enough fill metal of if you had to weave the electrode in order to complete a weld. If this should occur reducing your puddle size may allow you to have more control over where your fill metal flows.
Use standard sized metals – Using metals that come in a standard size will be easier for you to handle and produce a better weld. Using off sizes will make the welding process harder and your welds will suffer. It is important to use metals that are already pre-cut to the size that you need.
Know your arc length – In stick welding it is highly suggested that you use an arc length that is the same distance from the metal as the thickness of the electrode. It is also important to remember that as you continue to weld you will need to move your electrode closer to the metal in order to produce a high quality weld.
Mig Welding With Pulse
08.16.11
Pulsed MIG is a touchless transfer method between the electrode and the weld puddle. The electrode does not ever touch the puddle at any time. This is achieved through high-speed manipulation of the electrical output of the welding machine. It is intended to be a spatterless procedure that will operate at a lower heat input than spray or globular transfer techniques.
The pulsed MIG process is completed by forming one droplet of molten metal at the end of the electrode per pulse. Just the right quantity of current is added to drive that one droplet across the arc and into the puddle. The transmittal of these droplets arises through the arc, one droplet per pulse.
To understand this process better, look at a waveform. Unlike CV (constant voltage) where current is symbolized by a straight line, pulsed MIG drops the current at times when extra power is not necessary, thereby cooling off the process. It is this "cooling off" phase that allows pulsed MIG to weld better on thin materials, manage distortion and operate at lower wire feed speeds.
The current rises to a peak when the droplet is formed during the process. In the background current phase then, the current is dropped to condense the overall heat input. For proper transfer, it is the height and the width of the peak that is important.
Tig Welding With Thoriated Tungsten Electrodes
08.15.11
Tungsten electrodes are used when arc welding with the Tungsten Inert gas (TIG) process or when plasma welding. In both processes the electrode, arc and weld pool are protected from atmospheric contamination by an inert gas. A tungsten electrode is used because it can withstand very high temperatures with minimal melting or erosion. Electrodes are made by powder metallurgy and are formed to size.
Oxides used are primarily those of zirconium, thorium, lanthanum, yttrium or cerium. Additions are usually of order 1%-4%. All these oxides greatly improve arc initiation, especially when direct current (DC) welding is employed. Thorium oxide (thoria) has been used for many years having been found effective in terms of long life and thermal efficiency. Zirconium oxide (zirconia) has been commonly used for alternating current (AC) TIG welding, normally for welding aluminium.
Thorium oxide is, therefore, a low level radioactive material which may give rise to both a small external radiation hazard and an internal hazard from ingestion or inhalation. The external hazard estimated for a welder holding an electrode for a whole year is a very small fraction of the maximum permissible radiation dose and it is concluded that the external radiation hazard is likely to be negligible.
The Definition Of Plasma Cutting
08.12.11
Plasma cutting is a process that is used to cut steel and other metals of different thicknesses (or sometimes other materials) using a plasma torch. In this process, an inert gas (in some units, compressed air) is blown at high speed out of a nozzle, at the same time an electrical arc is formed through that gas from the nozzle to the surface being cut, turning some of that gas to plasma. The plasma is sufficiently hot to melt the metal being cut and moves sufficiently fast to blow molten metal away from the cut. The Pilot Arc type uses a two cycle approach to producing plasma, avoiding the need for initial contact. First, a high-voltage, low current circuit is used to initialize a very small high-intensity spark within the torch body, thereby generating a small pocket of plasma gas. This is referred to as the pilot arc. The pilot arc has a return electrical path built into the torch head. The pilot arc will maintain itself until it is brought into proximity of the workpiece where it ignites the main plasma cutting arc. Plasma arcs are extremely hot and are in the range of 25,000 °C (45,000 °F). Plasma is an effective means of cutting thin and thick materials alike. Hand-held torches can usually cut up to 2 inches (51 mm) thick steel plate, and stronger computer-controlled torches can cut steel up to 6 inches (150 mm) thick. Since Plasma Cutters produce a very hot and very localized "cone" to cut with, they are extremely useful for cutting sheet metal in curved or angled shapes.
Tig Welding Techniques For Welding Mild Steel
08.10.11
Mild steel is a steel alloy that has a low percentage of carbon, generally 0.3 percent or less. For this reason, mild steel is also called low-carbon steel. It is extremely common in fabrication because it is inexpensive compared with other steel alloys and is easy to weld. Mild steel can be welded using tungsten inert gas (TIG) welding techniques, and the result is a clean and precise weld.
Mild steel is generally the first metal that a new welder trains on, because of its ease in welding, but the TIG process requires more concentration and finesse than metal inert gas (MIG) welding or oxy-acetylene torch welding. Before welding mild steel, all workpieces and even the welding rod must be clean, as particulates can weaken the weld. For thinner sheets, the filler material may not be needed. The welder strikes an arc at the start of the weld, and creates a puddle, holding the electrode at a 10- to 15-degree angle from vertical. The electrode is pointed in the direction of the weld, and the welder "pushes" the molten metal forward by moving the electrode and the arc forward. The welder has to maintain a close tolerance between the electrode, the workpiece and the filler rod, without the filler rod or workpiece actually touching the electrode.
Mig Welding Stainless Steel
08.09.11
There are a few main differences between welding carbon steel and stainless steel.
Stainless steel requires a high percentage of Argon in the shielding gas mixture. The welding wire or electrode needs to be very close to the composition of the base metal. The transfer of the wire must be either globular or spray transfer. Finally the liner needs to be kept as straight as possible when welding.
The high percentage of Argon in the gas mixture is needed because stainless steel does not react well with oxygen or carbon dioxide gasses. In most experiences the most common gas mixture used is C2 and that is 98% Argon and 2% Carbon Dioxide. Other mixtures use a small amount of Oxygen added to the Argon. Even though Oxygen is what causes weld defects, in small percentages it helps the arc.
The welding wire chosen should be the same type as the base metal to be welded. The best way to choose a wire or electrode is to always consult with a welding supply store.
The high percentage of Argon gas also helps the arc to obtain this type of transfer. I have found globular works best with thinner metal and true spray transfer is better for thicker metal. But others may disagree. It comes down to personal preference and welding style.
Stick Welding Stainless Steel With A Longevity Stick Welder
08.08.11
Plug your welder into a 220V outlet and then plug in your ground cord and welder electrode holder cord into the welder.Welding stainless steel requires a special electrode. Purchase an AWS E308 stick electrode to weld stainless steel.Clean the surface to be welded with a wire brush.
Clamp the grounding clamp cord from the welder onto the piece of steel to be welded.Place an electrode into the welder electrode holder, position the electrode near where the weld will start and pull your helmet over your face.
Tap the electrode on the steel until it strikes an arc and begin to weave the electrode stick from side to side and always keep the arc a half a centimeter or less away from the piece of steel you are welding.
Allow the weld to cool off for a minute, then use the welding hammer to chip off the slag from the top of the weld.
Mig Welding Aluminum With A Longevity Spool Gun
08.06.11
when mig welding aluminum, the weld puddle is pushed and not pulled. You can also notice the cleaning action of the arc around the edges of the weld puddle that breaks up the aluminum oxide and allows the puddle to wet in to the base metal.
For 1/8" thick aluminum, unless you have the machine set just right, the slow steady bead just builds up too much heat because by the time you reach the edge of the metal, its really too hot and leaves a huge crater.The tip of the wire never goes into the puddle, Fine little droplets of metal "spray" into the weld. When you mig weld steel with "short circuit transfer" the wire actually fuses into the puddle and then arcs back many times a second and makes that bacon frying sound.
You do not want to hear a bacon frying sound when mig welding aluminum. IF you do, you have too much wire speed.
Another technique that I like better is to use kind of a step and pause technique where you hitch ahead quickly about a quarter inch and then pause...to the tune of about once every second.
It goes like this, move ahead and pause...thousand one...move ahead and pause...thousand two.. This step and pause welding technique puts ripples in the weld like a tig weld. Almost like a stack of dimes. Another benefit is it seems to build up less heat by moving quicker.
Stick Welding with E6010 and E6011 Electrodes
08.05.11
E6010 and E6011 are two American Welding Society (AWS) classifications for Shielded Metal Arc Welding (SMAW) electrodes (stick electrodes). These two types are very similar. Both are mild steel (60 ksi minimum tensile strength) electrodes with a cellulosic based coating for all-position, multiple applications welding. They have similar arc or operating characteristics and mechanical properties.
The main difference between the two is with the recommended welding polarity. E6010 electrodes are intended for direct current (DC) only. While E6011 electrodes can be used on alternating current (AC), as well as DC. More specifically, an E6010 electrode has a high-cellulose sodium-type coating and an E6011 electrode has a high-cellulose potassium-type coating. The latter helps keep the arc ignited as the welding output alternates from positive to negative. In perhaps over-simplified terms, an E6011 electrode is like an E6010 electrode designed to operate on AC polarity.
Protecting your skin from Welding UV Lights
08.04.11
Welding safety:
Protect all skin from UV light.Closing your eyes for a few sneaky tacks will not prevent arc eye.Work in a well ventilated area (extraction fans not blowing fans as those would blow your shielding gas away).Wear a vapour mask if your extraction isn't great.Be careful not to have flammable stuff nearby. Welding and grinding sparks can travel a long distance.
Welding arc eye:
The light generated by MIG welding is extremely bright. Looking directly at a welding arc even for a short time causes arc eye when the bright flash from the arc burns the cornea. The cornea is very sensitive to sun burn. Expect to be awake all night with the sensation that someone is sticking pins in your eye.
For sensible people wearing a full face welding mask it tends to be the reflected light that causes arc eye. Welding all day in a room with white painted walls can be enough. Welders caps aren't just to stop sparks.
Be very careful to warn anyone else in the area when you are about to start welding, and use a welding screen if welding in an area where there might be passers by. Be especially careful with pets and children - they can be as daft as a brush.
Tig Welding Aluminum Boat Propellers
08.02.11
When someone runs their aluminum boat prop into the lake bottom , usually it can be repaired by replacing the worn or chipped metal with weld metal. The problem is the any aluminum that has been in service like a boat prop or engine crankcase, soaks up some crap. Its like a sponge. Aluminum boat props always have some corrosion going on in the microscopic crevices of the metal and it seems to want to escape during the welding process. Sometimes, you dont notice it while you are welding and you think its all good until you blend off the weld.
There are a few tips that help buy on aluminum castings like boat props and crankcases, you will probably never have a weld that is completely free of porosity. Clean, clean , and clean , use a coarse carbide burr to dig out the rough fractured or worn surface. After that scotch-brite type abrasives work for removing paint and corrosion without embedding sanding or grinding grit. Follow with a good acetone wipe.
The key is PRACTICE PRACTICE PRACTICE before you even think about doing your own, expensive boat prop. Start learning on NEW 1/8" aluminum strips. Then, your best bet is to go to the junkyard and get some scrap aluminum parts like timing chain covers, or even aluminum heads. and PRACTICE running beads on some of the thinner edges. This will give you an idea of what happens on any aluminum casting when you light up on it with a tig torch.
How to start welding in stick mode
07.28.11
Welding is an important component of any metalwork job. The skill of welding can be highly valuable to learn because of the high cost to have repair and welding done. The cost of welding work ranges from $25-$50 an hour. Imaging doing it yourself to save money and learn a valuable trade. Welding stainless steel is becoming a highly demanded skill with the growing use of stainless steel in products. Stainless steel welding projects range from welding a cracked sink to welding a leak on a grain bin.
Plug your welder into a 110v/220V outlet and then plug in your ground cord and welder electrode holder cord into the welder.Welding stainless steel requires a special electrode. Purchase an AWS E308 stick electrode to weld stainless steel.You will also need to clean the surface to be welded with a wire brush.
Place an electrode into the welder electrode holder, position the electrode near where the weld will start and pull your helmet over your face.
Tap the electrode on the steel until it strikes an arc and begin to weave the electrode stick from side to side and always keep the arc a half a centimeter or less away from the piece of steel you are welding.
Allow the weld to cool for a minute, then use the welding hammer to chip off the slag from the top of the weld.
Now you are ready to Stick Weld.
Common Tig Welding Problems
07.26.11
TIG welding can cause difficulties for even the most experienced welders and certainly for novice operators. Still, these problems don’t have to slow you down. Arming yourself with some good troubleshooting skills can help you to get back to work…fast! Not to mention, these skills can save valuable time and money.Weld discontinuities, imperfections that adversely affect the integrity or strength of a weld, are common problems that can occur during TIG welding.
One such discontinuity is porosity, which is the formation of gas pockets in the weld metal. In many cases, porosity is visible with the naked eye in the form of small holes. In the instance of critical welds.Porosity in a TIG weld occurs as the result of one of more of the following factors: improper shielding gas coverage, the wrong filler metal or shielding gas, too much heat and/or a dirty base material.
To remedy the problem, be certain all torch fittings are tightened and visually inspect hoses for cracks that could be causing shielding gas leaks. If you are having trouble finding loose connections, apply soapy water to the hose and fittings until you find the leak and then tighten the fittings accordingly. Replace damaged hoses as needed.
How To Clean Welding Gloves
07.25.11
Welding gloves are an important part of any welder's equipment; not only do they protect you from burns caused by sparks, but they also guard your skin from exposure to the welding arc. What's more, clean and well-maintained gloves not only protect you, but they also help you do your job better. Properly cleaned gloves are softer and more pliable and allow you to better handle your equipment.
Prepare a mixture of anti-bacterial dish soap and warm water. Immerse your gloves in the soapy solution for approximately 45 minutes.
Thoroughly rinse off your gloves with cold water and thoroughly ring them out. Hang them up to allow them to air-dry (approximately 12 hours).
Apply a small amount of saddle soap to your gloves and rub it into the material. The saddle soap helps make your welding gloves more pliable.
Different Types Of Tungsten Electrodes For Welding
07.21.11
Description:
LONGEVITY 2% Thoriated Tungsten contains a nominal 2 wt-% or thorium oxide (ThO2) that is evenly dispersed throughout the entire length of the Tungsten. The most common type of Tungsten used today. Provides excellent resistance from weld pool contamination while at the same time offers the welder easier arc starting capabilities and a more stable arc. Generally used for DC electrode negative or straight polarity applications such as carbon & stainless steels, nickel alloys and titanium.
Description:
Pure Tungsten contains a minimum of 99.5wt-% Tungsten with no other alloying elements. This allows the tip to form a clean, balled end which provides good arc stability on AC. Pure can be used with DC but does not compare with Thoriated or Ceriated as far as ease of arc starting. More susceptible to weld contamination than Thoriated, Ceriated or Lanthanated. Usually the least expensive of all Tungsten. Pure Tungsten is generally used in the welding of aluminum and magnesium alloys (AC).
Description:
LONGEVITY 2% Ceriated tungsten contains a nominal 2wt-% of cerium oxide(CeO2). Ceriated is different from Thoriated as it is not a radioactive material. Ceriated Tungsten also tends to last longer than Thoriated and can be used proficiently with AC or DC. In manual applications the Ceriated Tungsten will provide slightly different electrical characteristics than the Thoriated Tungsten but generally no difference will be seen by the operator. Generally used to weld carbon & stainless steel, nickel alloy and titanium.
Safety Tips For Silent Generators
07.15.11
Generators should be operated in well ventilated locations outdoors away from all doors, windows and vent openings.
Never use a generator in an attached garage, even with the door open.
Place generators so that exhaust fumes can’t enter the home through windows, doors or other openings in the building.
Make sure to install carbon monoxide (CO) alarms in your home. Follow manufacturer’s instructions for correct placement and mounting height.
Turn off generators and let them cool down before refueling. Never refuel a generator while it is running.
Store fuel for the generator in a container that is intended for the purpose and is correctly labeled as such. Store the containers outside of living areas.
Plasma cutting Aluminum
07.12.11
Connect the compressed air source into the plasma cutter. Most portable units will need an auxiliary air source. In most cases, the plasma cutter may not even switch on until the air source is present.Switch the plasma cutter on. Allow the unit to go through a self diagnostic test. A green light will appear on the face of most models when the unit is ready for operation.
Set the tip of the hand held torch to the outside edge of the material being cut. The center tip hole, or torch cutting orifice, should rest just to the outside edge of the material.Depress the torch trigger. Air will immediately blow from the torch tip. One second later, the electrical arc will ignite.
Move the torch head tip along the material cut line. Hold the torch approximately 1/16 inch to 1/8 inch away and above the material. Do not drag the torch head along the surface as this will prematurely wear out the interior cutting tip parts.Continue to plasma cut the material until the full piece you desire is cut. Release the torch switch and the arc will cease. The compressed air will continue to blow from the tip for a predetermined time to cool down the hand held torch.
Aluminum Welding Techniques
07.01.11
Follow the rules of thumb offered here for selecting welding equipment, preparing base materials, applying proper technique, and visually inspecting weldments to ensure high-quality gas-metal-and gas tungsten-arc welds on aluminum alloys.
Base-metal preparation: To weld aluminum, operators must take care to clean the base material and remove any aluminum oxide and hydrocarbon contamination from oils or cutting solvents.
Preheating: Preheating the aluminum workpiece can help avoid weld cracking.
The push technique: With aluminum, pushing the gun away from the weld puddle rather than pulling it will result in better cleaning action, reduced weld contamination, and improved shielding-gas coverage.
Travel speed: Aluminum welding needs to be performed "hot and fast."
Shielding Gas: Argon, due to its good cleaning action and penetration profile, is the most common shielding gas used when welding aluminum.
Welding wire: Select an aluminum filler wire that has a melting temperature similar to the base material.
Convex-shaped welds: In aluminum welding, crater cracking causes most failures.
Power-source selection: When selecting a power source for GMAW of aluminum, first consider the method of transfer -spray-arc or pulse.
Wire feeder: The preferred method for feeding soft aluminum wire long distances is the push-pull method, which employs an enclosed wire-feed cabinet to protect the wire from the environment.
Welding guns: Use a separate gun liner for welding aluminum.
Constant-current (cc) and constant-voltage (cv) machines can be used for spray-arc welding. Spray-arc takes a tiny stream of molten metal and sprays it across the arc from the electrode wire to the base material.
In some shops, welders use the same wire feeders to deliver steel and aluminum wire. In this case, the use of plastic or Teflon liners will help ensure smooth, consistent aluminum-wire feeding.
Use drive rolls designed for aluminum. Set drive-roll tension to deliver an even wire-feed rate. Excessive tension will deform the wire and cause rough and erratic feeding; too-little tension results in uneven feeding. Both conditions can lead to an unstable arc and weld porosity.
Change liners often to minimize the potential for the abrasive aluminum oxide to cause wire-feeding problems.
Use a contact tip approximately 0.015 inch larger than the diameter of the filler metal being used - as the tip heats, it will expand into an oval shape and possibly restrict wire feeding.
Plasma Cutters & CNC Plasma Cutters
06.30.11
Plasma cutters have also been used in CNC machinery. Manufacturers build CNC cutting tables, some with the cutter built in to the table. The idea behind CNC tables is to allow a computer to control the torch head making clean sharp cuts.
Modern CNC plasma equipment is capable of multi-axis cutting of thick material, allowing opportunities for complex welding seams on CNC welding equipment that is not possible otherwise. For thinner material cutting, plasma cutting is being progressively replaced by laser cutting, due mainly to the laser cutter's superior hole-cutting abilities.
A specialized use of CNC Plasma Cutters has been in the HVAC industry. Software will process information on ductwork and create flat patterns to be cut on the cutting table by the plasma torch. This technology has enormously increased productivity within the industry since its introduction in the early 1980s.
In recent years there has been even more development in the area of CNC Plasma Cutting Machinery. Traditionally the machines' cutting tables were horizontal but now due to further research and development Vertical CNC Plasma Cutting Machines are available. This advancement provides a machine with a small footprint, increased flexibility, optimum safety, faster operation. Our LONGEVITY cnc compatible Plasma Cutters work great with CNC tables also they use the IGBT technology to help perform a more precision cut and last longer over time.
How To Prepare Your Metal For Welding
06.29.11
Preparing metal for welding is a very important step in the welding process. If your metal is not prepared properly, you can compromise on the integrity of the welds themselves. It pays to take time with the preparation of the metal to ensure you have the best welds possible.
Check the metal before welding it. If the metal has a coating, which could possibly be a thin layer of metal, you must remove it. You can use a grinder to prepare the surface of the metal for welding.Clean the metal of any rust when you are preparing metal for welding. Metal on a car can be rusty, and before welding anything onto it, you'll need to take off any rust spots with a grinder or steel wool.
Try different techniques for cleaning metal as you prepare it for welding. Straight or flat grinders work well, but for metal of different shapes, you might want to use an angle grinder.Take off any bad welds with a grinder when you are preparing metal for welding. Removing a bad weld and starting over is often better than trying to make a bad weld better. Starting fresh means that you can now create a fresh, clean weld that will be nice and strong.
Use a grinder to clean the edges of the metal when you are preparing to weld metal together. By having clean edges, you can ensure that the weld will be solid and hold well.Wear your safety glasses when you are preparing metal for welding.
3 Phase Electrical Power
06.27.11
3 phase power is a common form of electrical power and a popular method of electric power transmission. This is due to its inherent benefits for high power transmission and its smooth wave form quality which allow 3 phase electrical equipment to run smoothly and last longer. There are many other benefits to 3 phase power. Three phase has properties that make it very desirable in power distribution. First, all three wires can carry the same current. Secondly, power transfer is constant into a linear and balanced load. Most domestic utility supplied power is single phase only. In most cases three phase power either is not available from a utility company to domestic houses, rural business and farms, at all, or in rare cases where it is, it is split out at the main distribution board. See 3 phase power generating phase converters for solutions to getting 3 phase power where utility companies do not offer it or where it is cost prohibitive. The 3 phase power generated from some of today's high quality Rotary Phase Converters is better balanced with closer voltage tolerances and a smoother wave form than utility supplied power. For this reason the 3 phase power output from these 3 phase generating converters is preferred for sensitive equipment than what is available from utility supplied 3 phase power.
Tips For Welding Aluminum
06.22.11
Always make sure that you have the proper personal safety equipment. Wear good welding gloves, a helmet, leathers, and everything else you need to ensure that you will not be injured. Welding aluminum is just as dangerous as welding steel. If you use a TIG welder, keep in mind that it will produce more UV radiation than other welding processes do. This means that your skin will be burned to the point of peeling and blisters in just a few minutes if you do not take precautions, similar to a severe sunburn. A heavy work shirt with long sleeves will prevent this painful occurrence.
You need argon gas to weld aluminum. If you want to use a mix, the only one that you can use is a mixture of argon and helium. Other mixes will not work with aluminum. You also need a welding rod that is made for aluminum. You can find charts online that will tell you the recommended welding rods for aluminum. You should have a steel brush that is used only for aluminum to brush it off.
Before you begin, always clean the aluminum. Even if the aluminum looks brand new and clean. It is still dirty and needs to be cleaned. If you are wondering if your aluminum is dirty, there are several ways to tell, such as: the arc wanders, the filler won't blend but rolls into a ball, the aluminum has surface tension and joining pieces curl away from each other. Spray the aluminum with acetone, rinse with water, let dry, and use a stainless steel brush to scrub it clean in the welding area.
High Frequency Welding
06.20.11
High Frequency welding is a process which uses an electric field to create the heat needed to melt a metal/metal joint. The field is created when the metal to be welded is passed through a copper coil, both the metal to be jointed and the copper coil have the ability to magnetise. Metals commonly welded using this process are stainless steel and aluminium. This is actually the preheat and heating stage of the tube similar to preheating of a flat weld piece before welding to make it molten/softer before actual welding.
Radiators in your car are made from aluminium components and the primary component in the radiator, which is the tube, is produced through this process. The process entails running a flat metal sheet through different welding stations which gradually fold the flat sheet into an oval shape or for b-type tubes into a rectangular shape.
After folding both ends of the sheet will meet forming the weld joint, ideally the joint must resemble a flat butt weld joint. But since sheets are cut using blades which are subject to wear and tear, the ends of the joint might have a V-like surface creating a V-joint instead.
Tips about Aluminum
06.17.11
Here are some of the signs that your aluminum is dirty:
A wandering arc -You can’t get a puddle started without burning through or distorting the metal. Your filler won’t blend into the puddle, instead it rolls into a difficult to re-melt ball. The aluminum seems to have surface tension, like beads of water on a waxed surface. When trying to join 2 pieces the edges curl away from each other and form an even bigger gap.
Here's what's happening:
Aluminum quickly forms an more or less invisible coating of aluminum oxide. Aluminum oxide melts at three times the temperature of aluminum. When you try to weld uncleaned aluminum, the aluminum under the aluminum oxide coating will melt but the aluminum oxide coating will stay solid and act as a membrane, much like a water balloon. When you finally succeed in penetrating the coating, the very runny aluminum inside will flow out all at once, much like a bursting water balloon.
Here’s how I prep the aluminum for welding:
First, I spray the aluminum with acetone. Don't use brake cleaner unless it's 100% acetone. Then, I rinse the aluminum in water, just in case there's any nasty residue. The aluminum should be completely dry before welding, including all of the nooks and crannies.
Then, I use a stainless steel brush (make sure the brush is stainless, I've read this is important) to scrub the aluminum shiny clean around the area to be welded.
Diesel Generator Safety Tips
06.13.11
Always make sure that generator set is properly grounded. Calculate the Power Output first before application of real load to generator sometimes portable generator creates power loss when the generator engine overloads,keep the generator location neat and dry.
The wiring of power generation system should be immaculate, be sure that the wiring should not be worn out. In case of any loose connection it can cause an uncertain electrical shock.
Do not try to operate diesel generator in unclosed area, the exhaust of diesel engine produces carbon monoxide CO which is harmful for human health so it is recommended that diesel generators exhaust system should be make free in open system. Diesel Generator operating surface should be inclined in nature because in form of any other surface generator may cause problems in cranking properly.
Keep the generator fuel in safe and closed state, label the container or bottle clearly so it may be easier to prominent fuel nature for everyone.
Advantages and Disadvantages of Mig Welding
06.09.11
Advantages of Mig Welding:
MIG Welding is a much faster process than Stick welding,The operating cost of MIG welding is lower than Stick welding because of the time savings, and because there's virtually no waste of filler metals (50 lbs. of MIG welding wire yields approximately 49 lbs. of deposition, as compared to Stick welding where as much as 25% of each electrode is discarded as stubs).In general, thinner materials can be welded more easily with MIG versus Stick welding. MIG welding is a clean process and does not require chipping slag off the weld as in Stick welding.
Disadvantages of Mig Welding:
Initially, it costs more to set up a MIG system than a Stick welder, because of regulators and shielding gas (some MIG welding is done with self-shielding flux core which does not require gas or a regulator). You are strictly looking at dollar per amp, Stick welding is cheaper.
Pulsed Arc Welding
06.08.11
Pulsed Arc Welding is a direct-current welding system in which the pulsing current is superimposed on a constant voltage d-c current.
Pulsed Arc Welding is an adapted form of gas metal arc spray transfer welding, which produces a controlled and periodic melting off of droplets which are projected across the arc. This procedure allows Arc Welding at average currents which are considerably lower than the steady-state current necessary for Arc Welding. The method allows welding of thin sheet metal which would be melted through by the standard GMAW process. During the pulsed arc procedure the filler wire is heated by the background current and the end may start to melt into a drop. When high current pulses occur, the drop melts completely and is propelled by the arc pinch effect, directly from the wire to the weld pool. One or more drops may be propelled across the arc during each pulse. The pulsed arc mode produces deeper penetration and better root fusion than the dip transfer, or short circuiting mode. For this reason, pulse Arc Welding is particularly suited to welding the thinner materials.
SS and Aluminum Stick Welding Electrode Comparison
06.03.11
All welding is the process of participating. heat produced by the fusion of the two is the right temperature to make. Collage by adding a bar packed or linked. This is the basis of the connection in the form of rawest there are two types.nonferrous metals Ferrous iron in the family and the difficulty Tours to see steel put magnets in the game if sticks and iron.
There are non-ferrous metals are not magnetic. They are aluminum, magnesium, copper and lead. Now go to the Plasma arc welding is a process connected with production by heat. the electric arc and a decrease in room Protected from the hot gases from the fresh mouth, which may be supplemented by that to help prevent gas To prevent gas. Have access to clean, will not be contaminated by the atmosphere.
This air carbon arc cutting. Cutting metal with temperatures across when liquid carbon arc metal from the blast of air. Plasma Cutting and is popular for cutting metal. Only draw back is the only device that is very expensive when compared to single oxyfuel cutting torch
Air Cooled Tig Torch Vs. Water Cooled Tig Torch
06.02.11
First lets clear up a few misconceptions about exactly what an air cooled tig torch is. It is not cooled by forced air but rather it is called an "air cooled tig torch" only to distinguish it from a water cooled tig torch. The air cooled tig torch is also called a "dry rig" because it uses no water for coolant. Heat just dissipates off the torch into the air. A dry rig tig torch is always larger than a water cooled tig torch that has the same amperage rating.
The torch cable on an dry rig torch is also much larger. A water cooled torch has a much smaller power cable. It can be small because it is inside a plastic tube thru which coolant is pumped. As long as there is coolant flowing over the power cable, it stays cool and will handle a lot of amperage. If the coolant stops, the torch cable will heat up and usually burn right through the tubing.
Air Cooled Torch Pros
o simple with low maintenance
o no cooler recirculation unit required
o cheaper than water cooled
o more portable
Air Cooled Torch Cons
o Larger than water cooled torches with the same amperage rating
o Get hotter in your hand
o Not available in high amperage ratings
Water Cooled Torch Pros
o smaller torch
o high amperage torches available
o stay cool
Water Cooled Torch Cons
o cooler /recirculation unit required and they are expensive
o more expensive than air cooled torches
o more complicated to hook up
o some maintenance is required on the coolant system
How to wire a Plasma Cutter
06.01.11
A plasma cutter is a device that uses energy to its advantage. It consists of a nozzle with two passages for gas and a central negative electrode for basic functioning. It is charged with electricity and remains closed to the metal to be cut. It generates a very hot spark when it starts cutting. Argon gas flows from the closest passage around the arc, which is really hot, and then causes the molecules to move at an extremely fast rate. This causes collision, and thus, a large amount of energy is released. In order to contain the unpredictable arc into a confined area, in a second passage flows a strong shielding gas. The plasma cutter builds a strong 30,000 degrees Fahrenheit, which is capable of cutting pretty much anything. It is able to cut through seemingly-impenetrable sheets of metal like melted butter. Wiring a plasma cutter is not as tough as you may think it is. All it takes is some precision and safety precautions for your own sake.
Tips for underwater welding
05.31.11
There are two major types of underwater welding--wet and dry. They both are a form of hyperbaric welding, which is a high pressure welding method. Wet welding takes place in a completely wet setting. Dry underwater welding is performed in a dry chamber. The area needing fixed is surrounded with a chamber and the water is pumped out. The welder works inside of this dry chamber.
Underwater welders have a danger of electric shock. Numerous precautions must be taken to prevent this situation. This includes insulation on equipment and turning off the power instantly when the welding is finished. There are also risks of explosions from combinations of oxygen and hydrogen pockets being ignited. Another serious danger is from nitrogen accumulating in the welders' bloodstream from the high pressure. Decompression chambers and extra divers are used to avert this danger.
Safety Tips For Generators
05.27.11
When operating stationary or portable generators, safety should be a primary concern. Taking certain preventative measures ensures many years of safe use. Even small generators are an investment so consumers want them to be ready for use when needed. Safe operation will not cause any damage to a property or its occupants.
• A generator should not be plugged directly into a home outlet. If the generator will be connected to the home electrical system, a power transfer switch should be installed by an electrician.
• If an extension cord is used with the generator, it should be grounded and rated for such use. A coiled extension cord can get hot, so uncoil the cord and lay it flat in an open location.
• Several safety measures pertain to the use of fuel, whether using gasoline, propane, or diesel generators. If a gasoline model is being used, the fuel should be fresh. Gas can be stabilized with a fuel stabilizer if the generator will not be used for 30 days. Let the engine cool at least two minutes before refueling because gas and gas vapors are flammable.
• Generator engines emit carbon dioxide, which is one reason the unit should not be run in an enclosed area. Open windows and doors do not create enough air flow. When running the generator, use a carbon monoxide detector that is battery powered in order to detect unsafe levels of carbon monoxide.
Stainless Steel Welding Procedures
05.23.11
Stainless steel alloys usually have a chromium content of a least 10%. Stainless steel base metals are grouped primarily into three classes depending on their crystal structure; austenitic (such as 302, 304, 308, 316, etc.), martensitic (such as 410, and 416), and ferritic (such as 409, and 430.). Austenitic grades are also available with a lowered carbon content (designated with an "L", such as 304L or 316L.)
Safety
Before use, read & understand the manufacturer's instructions, Material Safety Data Sheets (MSDS) & your employer's safety practices.
Keep your head out of the fumes.
Use enough ventilation; exhaust at the arc, or both, to keep fumes & gases from your breathing zone & the general area.
Wear correct eye, ear, & body protection.
Do not touch live electrical parts.
See American National Standard Z49.1, Safety in Welding, Cutting, & Allied Processes, published by the American Welding Society, 550 N.W. LeJeune Road, Miami, FL 33126; OSHA Safety & Health Standards, available from the U.S. Government Printing Office, Washington, DC 20402
Start by determining the best manner in which to join your base metals. Correct joint design & fit up are critical steps to insuring a strong bond upon weld completion. Be sure to consider strength required, welding position, metal thickness & joint accessibility.
The five basic types of joints are butt, corner, edge, lap & t. These five joints can be arranged in many combinations to create a large variety of welds. Fixtures & jigs are helpful in securing the work pieces in place during the joining procedure. Sheet metal & most fillet & lap joints should be clamped tightly over the entire length of the work.
DC uses either straight polarity, which is electrode negative or reverse polarity, which is electrode positive. Direct current flows in one direction continuously through the welding circuit. There are several advantages of DC. It works well at low current settings & with small diameters. In addition, igniting the arc & maintaining a short arc is easier.
Stainless electrodes designated Ð15, (ex: 308-15) use direct current, reverse polarity. Their key characteristic is fast freezing slag, which make them suitable for out of position welding. Bead appearance is convex.
How A Generator Works
05.19.11
How A Generator Works!
An electric generator is a device that converts mechanical energy obtained from an external source into electrical energy as the output.
It is important to understand that a generator does not actually create electrical energy. Instead, it uses the mechanical energy supplied to it to force the movement of electric charges present in the wire of its windings through an external electric circuit. This flow of electric charges constitutes the output electric current supplied by the generator. This mechanism can be understood by considering the generator to be analogous to a water pump, which causes the flow of water but does not actually create the water flowing through it.
The modern day generator works on the principle of electromagnetic induction. The flow of electric charges could be induced by moving an electrical conductor, such as a wire that contains electric charges, in a magnetic field. This movement creates a voltage difference between the two ends of the wire or electrical conductor, which in turn causes the electric charges to flow, thus generating electric current.
How to clean Aluminum Metals for Welding
05.18.11
Aluminum by itself isn't all that useful. It's too soft. Under most circumstances it is mixed with other metals like copper, zinc, magnesium, or manganese to create an alloy with greater strength and durability. Even with other metals thrown in there, aluminum alloys are still quite malleable and can be used for an absolutely ridiculous number of things. You will find aluminum used for cans (of course), pots and pans, utensils, siding, boats, machinery, wheels, motors, gutters, blinds, electrical work, paints, and the list goes on and on and on. It makes good sense, along with being cheap, abundant, and easy to work with, the stuff is also very resistant to corrosion. This is due to aluminum's affinity for oxygen.
Give it a thorough scrubbing. More than likely, your piece of aluminum has acquired a nice layer of dust. The first step to aluminum cleaning is to wash it. There's no special trick to this. Fill your sink with hot water and soap and wash away. Make sure to remove all of the grease or you won't be able to penetrate it later to get rid of the aluminum oxide underneath. You may need to use a scratchy pad. Make sure to get in the edges really well.
Safety Tips For Plasma Cutting
05.13.11
1) Eye Protection - Since the plasma cutting arc produce highly intense flare, fumes and rays. It is very important that you wear eye protection gear such as the face welding shield or welding goggle to prevent your eyes from getting burn or damage by these rays. It is also a good practice to alert anyone that might be within close range and can expose themselves to these dangers.
2) Ear Protection - A plasma cutting system can produce high level of noise, so you will want to wear some type of ear plug to prevent any harmful pitch damaging your ear drum. Yes! Long term exposure can lead to inreversible damages!
3) Clothing - Like operating in any kind of machinery, it is very important that you wear protective clothing. As explained before, the plasma arc can produce some visible and invisible rays that can actually damage your skin, so you will want to wear clothes that will help protect your skin from these type of exposure. Another reason is because the plasma system generate alot of voltage and electro magnetic field, so wearing the right clothings can prevent yourself from these harmful sparks, if not deadly shocks.
4) Shock Resistant Gloves - As explained above, in order for the plasma system to function, it requires alot of voltage and therefore as the system runs, it will generate an electric circuit around the working area, mostly the cutting piece and the torch tip of the arc. You should never touch any of these or anything that's touching these, as the shock can be extremely harmful. You will want to wear something like the shock resistant gloves to reduce the damage to the minimal, in case you accidently touch the work piece during operation.
5) Avoid Wet Environment - You should NEVER operate a plasma cutter in a wet or moist environment. This is for the very same reason that plasma cutters operates under very high voltage and exposure to wet environment and surfaces can be fatal. It is also advisable that you keep your working area dry at all times.
6) Beware of Fire - Since the whole operation generates flying spark, including but not limited to ultra violet and infrared rays. You should make sure that there are no flamable materials around you. For example dry paper, gas tank etc.
7) Toxic Gas and Air - Cutting through metal and similar materials can produce toxic fumes and gases, therefore it is ideally that you work in a well ventilated or open work area to avoid yourself from breathing in too much toxic gas which can create health problems. It is also advisable that you wear some type of respiratory protection gear, like those thin breathing masks or respirator.
8) Insulation - Avoid uneccessary electric shocks by wearing correct safety shoes and it is also important that you have a dry mat or covers where you can stand on to reduce the earth and ground physics.
9) Use Common Sense - Many safety measures are based on common sense. For example, if you believe the plasma cutting machine is broken or faulty, then please do not use it and consult or even return the product to your manufacturer for proper safety checks. This is just one example of using common sense, so please use it!
Underwater Welding
05.12.11
Types of Underwater Welding
Underwater welding can be divided into two main categories - dry welding and wet welding. Both these come under the category of hyperbaric welding. Hyperbaric welding method is a high pressure welding method. Wet welding takes place in a setting which is completely wet and dry underwater welding takes place in a dry chamber. In dry underwater welding, the area which is supposed to be mended is encircled by a chamber and the water in pumped out totally from that area. The underwater welder then performs his repairing work inside this chamber. This chamber is totally dry even when it is underwater and hence, it is known as underwater welding. This is really an interesting underwater welding information. More on welding tips and techniques.
Underwater Welding Dangers
It is very necessary to have all the underwater welding information because there are certain underwater welding dangers which a welder may have to face. A person who aspires to become an underwater welder should love adventure and should be ready to visit any kind of locations. Let us see the underwater welding dangers in more detail.
There are chances of getting an electric shock in underwater welding. Underwater welders have to take many precautions due to this danger. The precautions to avoid electric shock include use of equipments which are adaptable underwater, the power should be switched off immediately after the completion of the welding work and the welding current should be under control.
Another major risk is explosion. The formation and combination of hydrogen and oxygen pockets are dangerous because they are explosive and when ignited, they can lead to an underwater explosion.
Another danger is the accumulation of nitrogen in the bloodstream of the welder due to high pressure. Decompression chambers and extra divers are provided to the welders as precautions for this danger.
Plasma Cutting Techniques
05.11.11
Fabricators, contractors, maintenance personnel, artists, and do-it-yourselfers who experience a hand-held air plasma arc cutting machine rarely want to return to oxyacetylene cutting or mechanical cutting processes such as saws, cutoff wheels, shears, and snips.
Plasma cutting can improve productivity and lower cutting costs. It does not require a preheat cycle, cuts any metal that conducts electricity, permits portability around job sites, minimizes the heat-affected zone (HAZ), and yields a cut with a small kerf. Plasma units also can gouge, pierce, bevel, cut holes, and trace shapes.
Cutting Techniques
Step 1: Place the drag shield on the edge of the base metal, or hold the correct standoff distance (typically 1/8 inch). Direct the arc straight down.
Step 2: Press the trigger. After two seconds of preflow air, the pilot arc starts.
Step 3: Once the cutting arc starts, move the torch across the metal.
Step 4: Adjust speed so that the cutting sparks go through the metal and out the bottom of the cut.
Step 5: At the end of a cut, angle the torch slightly toward the final edge, or pause briefly to sever the metal completely.
Step 6: To cool the torch, postflow air continues for 20 to 30 seconds after you release the trigger; pressing the trigger during postflow instantly restarts the arc.
How to test Ceriated Tungsten Electrodes
05.10.11
Sharpen your ceriated tungsten electrode using an electrode sharpener. Sharpen the tip of the electrode until it has reached a point. Set your welding equipment to operate at an amperage level that is appropriate for your job specifications. This amperage level shouldn't exceed 200 amps for most tungsten electrodes. Perform at least one inch of welding with your ceriated tungsten electrodes.
Observe the state of the ceriated tungsten electrode. If the electrode is still sharp, then it will function perfectly at the specified amperage level. If the electrode is covered with nodules or bumps, or if the electrode point begins to curl, then you are unlikely to observe optimal performance at the specified power level.
Welding Rods
05.09.11
There are a lot of different welding electrodes and wires out there. In the field, welding electrodes are usually referred to as "welding rods" so I will use that term as well.
"Stick Welding" is also the term of choice in the field for SMAW, the acronym for Shielded Metal Arc Welding.
Stick welding used to be done with a bare welding rod. It was very difficult, and could only be used in the flat position. If you've ever stuck a rod with flux on it, you can only imagine how many times they stuck bare rods! If the rod gets too close to the base metal it will decrease the voltage causing the arc to go out.
Sticking the welding rod is where the rod instead of melting like it should, sticks to the base metal. There is not enough current to melt it, but enough for it to stick. One way of getting it loose is immediately jerking the rod away from the base metal. If that doesn't work, you have to unclamp the rod, and then break it off.
If you jerk the "stinger" (electrode holder) quick enough you can break the rod off of the base metal and re-strike your arc. But if it stays there too long and gets too hot, it will easily stick again and should be put down and allowed to cool.Many times when it sticks, the jerking away, or breaking loose of the rod will cause flux to come off of the end. That makes it really hard to strike and arc again without it sticking.
The different types of Plasma Cutting and Welding
04.21.11
Water Cooler: The work of water cooler is to cool the welding machines which get heated while welding. The welding heats up the torch of welders which needs a supply of water. Apart from these welding equipments you also need a welding helmet which protect for eyes and face from any harmful burns or sparks.
Plasma Cutting: One of the most important things used for any construction is the metal. Metals play a vital role in constructing buildings. Now to cut the metals you need a cutter. There are some cutters which doesn’t cut all kind of metal. But there is one cutter which can cut all the metal in no time. It is known as plasma cutter. These cut the metal with the help of plasma torch. These are utilized for cutting steel and all conductive metals. These cutters need high voltage and are epitomized of plasma gas. To make use of this first the plasma gas is created. The advantage of this is it can cut any metal at high speed. While cutting the inner surface remains cool and this does catch fire in any circumstances.
You can find many types of welders for welding objects like steel, aluminum and many other metals. Some of the welding equipments are Mig weld or GMAW, Tig weld or GTAW, Stick weld or SMAW, Spot weld and Arc weld. All these have different purpose and used for different industries. You can also find multi purpose unit which consist of plasma cutter, Mig weld, Tig weld and stick weld. They are the most versatile equipment because the space they need is really very less. Buying has made easy by shopping online. Now you can search and learn more about this product on net. Almost all the products have advantages and disadvantages.
Mig or GMAW weld: This metal inert gas is other wise known as Gas Metal Arc weld. These utilize the wire electrode and also needs constant voltage supply. These are mostly used for building aircraft and automobiles. These are the easiest among the welders. You need a lot of practice before welding metals.
Tig or GTAW weld: The other name for tungsten inert gas is the Gas Tungsten Arc welding. These are used for welding steel and non ferrous metal. These are easy to mechanize and automate. These are utilized in chemical and instrument industries. This gives a clean finish and are bit difficult for the beginners. These are highly pricey than the Mig welder and other welders.
Arc Force for Welding
04.20.11
Arc force is adjusted according to the type of electrode being used. A Rutile, or general purpose (6013) type electrode requires less arc force than for expample a basic coated electrode (7018) type. The highest arc-force is required for running pure Cellulose electrodes. Some MMA machines which have arc-force adjustment will be calibrated according to the electrode type, to make it easier to select the correct amount required. The parameter being changed is the actual welding voltage.
Arc force is commonly called Dig, Arc control and a few other terms. In SMAW arc force control is an automatic response of a welder to boost amps as the voltage falls due to the arc voltage dropping as the rod is pushed closer and into the puddle. Remember welding relies upon total watts not just amps. On a Constant Current machine, without arc force control, noticeable sticking can occur, especially cellulose rods. The arc force jumps in and increases current to make it a variable current( to a limited extent) machine as you are trying to gain control over the weld puddle by pushing in closer.
Technique's for Plasma Cutting
04.19.11
1. Determine The Thickness of the Metal that You will Most Frequently Cut
One of the first factors you need to determine is the thickness of metal most frequently cut. Most plasma cutting power sources are rated on their cutting ability and amperage. Therefore, if you most often cut ¼" thick material, you should consider a lower amperage plasma cutter. If you most frequently cut metal that is ½" in thickness look for a higher amperage machine. Even though a smaller machine may be able to cut through a given thickness of metal, it may not produce a quality cut. Instead, you may get a sever cut which barely makes it through the plate and leaves behind dross or slag. Every unit has an optimal range of thickness -- make sure it matches up with what you need. In general, a ¼" machine has approximately 25 amps of output, a 1/4" machine has a 50-60 amp output while a ¾" - 1" machine has 80 amps output.
2. Select Your Optimal Cutting Speed
If you are performing long, time-consuming cuts or are cutting in an automated set-up, be sure to check into the machine's duty cycle. Duty cycle is simply the time you can continuously cut before the machine or torch will overheat and require cooling. Duty cycle is typically rated as a percentage of a ten-minute period. For example, a 60 percent duty cycle at 60 amps means you can cut with 60 amps output power continuously for six minutes out of a 10-minute period. In general, the higher the duty cycle, the longer you can cut without taking a break.
The transfer from pilot to cut occurs when the pilot arc is brought close to the work piece. A voltage potential from nozzle to work is mechanism for this transfer. Traditionally, a large resistor in the pilot arc current path created this voltage potential. This voltage potential directly affects the height at which the arc can transfer. After the pilot arc transfers to work a switch (relay or transistor) is used to open the current path.
Pulse for Welding Metals
04.18.11
Some of the latest technology power sources on the market today are those that provide pulsing capabilities. Most likely, you have heard how these sophisticated machines make welding easier for the operator and provide a high quality weld. But, did you know that these machines actually provide a cost savings? Although you may pay a little more for these power sources initially, the advantages that they provide will decrease overall welding costs and provide a payback of your investment in the long run.
Advantages provided by pulsing machines include:
Wire and gas savings.Pulsed MIG machines offer a wider operating range because they extend the low and high range of each wire diameter. For instance, before the operator would have to stock .035”, .045” and .052” wire diameters for varying applications, but with Pulsed MIG, .045” can be extended on the low end and top end range so that it can be used for a variety of applications. What this means is that rather than having two or three different sized wires, an operator would only require one. Having one wire type minimizes inventory costs and reduces changeover times. The same is true with shielding gas – one gas can reach both the low and high ranges of the application. In addition, the different types of spare parts (gun, gun tips, liners, etc.) are decreased for additional cost savings.
Spatter and fume reduction-Compared to Conventional MIG, Pulsing offers reduced spatter and fume. Reduction in spatter translates into significant cost savings because more of the melted wire is applied to the weld joint, not as surface spatter on the product and surrounding fixtures. This also means less clean-up time. A reduction in the welding fumes creates a safer and healthier environment for the entire plant or shop.
Heat reduction- Pulsing offers controlled heat input leading to less distortion and improved overall quality and appearance which means fewer production problems. This is especially important with stainless, nickel and other alloys that are sensitive to heat input.
Improved productivity- Pulsed MIG offers high deposition rates. In addition, since the new machines are simpler and adaptive, it is easier to weld with pulsed MIG than other transfer methods, less time is spent training.
Better quality- All these advantages of Pulsed MIG outlined above result in overall better quality of the finished and a more stable arc. In addition, operators are receiving a better quality working environment since they are not dealing with fume, spatter and extra clean-up or grinding time. One more benefit is that synergic power sources allow for these high quality welds to be achieved by those with relatively less training.
Pulsed MIG is an advanced form of welding that takes the best of all the other forms of transfer while minimizing or eliminating their disadvantages. Unlike short circuit, pulsed MIG does not create spatter or run the risk of cold lapping. The welding positions in pulsed MIG are not limited as they are with globular or spray and its wire use is definitely more efficient. By cooling off the spray arc process, pulsed MIG is able to expand its welding range and its lower heat input does not make burn through on thin metals a problem.
Pulsed MIG is one of the best welding processes for a wide variety of applications and metal types.
IGBT Plasma Cutters
04.11.11
The IGBT is a fairly recent invention. The first-generation devices of the 1980s and early 1990s were relatively slow in switching, and prone to failure through such modes as latchup and secondary breakdown. Second-generation devices were much improved, and the current third-generation ones are even better, with speed rivaling MOSFETs, and excellent ruggedness and tolerance of overloads.
The extremely high pulse ratings of second- and third-generation devices also make them useful for generating large power pulses in areas like particle and plasma physics, where they are starting to supersede older devices like thyratrons and triggered spark gaps.
Their high pulse ratings, and low prices on the surplus market, also make them attractive to the high-voltage hobbyist for controlling large amounts of power to drive devices such as solid-state Tesla coils and coilguns.
Plasma Cutting Process
Plasma cutting, simply stated, is the process for cutting steel and metal of different sizes and thickness using a plasma torch. During plasma cutting, the inert gas or compress air used in some machines is ejected at high speed from the nozzle, while simultaneously, an electrical arc is made from the gas of nozzle to the surface to facilitate the cutting.
This plasma is adequately hot to melt the metal that is cut and it also moves fast to blow the metal far from the present cut. Additionally plasma arc cutters and several other applications also deploy the Insulated Gate Bipolar Transistor (IGBT) plasma cutting technology to provide more commercial plasma cutting equipment.
Arc Welding
04.04.11
Arc welding is a type of welding that uses a welding power supply to create an electric arc between an electrode and the base material to melt the metals at the welding point. They can use either direct (DC) or alternating (AC) current, and consumable or non-consumable electrodes. The welding region is sometimes protected by some type of inert or semi-inert gas, known as a shielding gas, and/or an evaporating filler material. The process of arc welding is widely used because of its low capital and running costs. Getting the arc started is called striking the arc. An arc may be struck by either lightly tapping the electrode against the metal or scratching the electrode against the metal at high speed.
One of the most common types of arc welding is shielded metal arc welding (SMAW), which is also known as manual metal arc welding (MMA) or stick welding. An electric current is used to strike an arc between the base material and a consumable electrode rod or 'stick'. The electrode rod is made of a material that is compatible with the base material being welded and is covered with a flux that protects the weld area from oxidation and contamination by producing CO2 gas during the welding process. The electrode core itself acts as filler material, making a separate filler unnecessary. The process is very versatile, requiring little operator training and inexpensive equipment.
Gas Cutting Questions For Application Issues
03.31.11
[1]When evaluating the fuel gas cost, examine how many cubic feet of gas a pound of the fuel gas provides. [2] Examine the cutting oxygen requirements necessary for the fuel gas selected. How much cubic feet of oxygen will you need for a cubic foot of fuel gas? [3] Are you concerned with distortion, if so do you want a fuel gas that has high heat in the secondary flame? [4] As the biggest influence on high volume cutting production is the start times to establish the cut, perhaps you should look at the concentrated heat available in the primary flame. [5] Cutting those steels over 25 mm thick and you frequently loose the cut perhaps there is not enough heat available in the secondary flame. [6] Perhaps at your plant, you need a fuel gas that is good for both welding and cutting. [7] Perhaps you have safety concerns about the storage of the fuel gas at your facility. Examine how temperature effects that fuel gas, the potential for flash backs or how certain fuels decompose at relatively low working pressures. [8] Possibly you will be cutting in a contained area with poor ventilation and you want to know how dangerous the fuel gas can. You should always be concerned about leaks and know which fuel gases are lighter than air. [9] If you don't do a lot of cutting and Nat gas is available in the building well the gas choice may be a no brainer. However if the Nat gas is slowing down your production, perhaps it's time to do a cost analysis for a different fuel gas.
The Convenience Of Using A Genenrator
03.28.11
Electricity is additionally limited. Its makers conjointly depend on the natural resources in manufacturing electricity or power. It's been already observed by many scientists and engineers that is why they came up with the concept of inventing a generator. Generators are machines that are used throughout the absence of electricity. It is the one being used in its place throughout blackouts. It will eventually offer electricity in a certain household with the employment of gasoline. However the facility of generators is also very abundant limited. The power of performance of a bound generator can rely on its size and capability to provide power. These machines are very much useful in terms of emergency and other unexpected power shortage. It will simply light-weight an entire household with the assistance of gasoline. The machine mainly uses a gasoline and battery to provide electricity. It is designed to allow humans to continue with their works despite the absence of electricity.
However the ancient types of generators have many disadvantages. One of these disadvantages is that the noise that it produces whereas you're using it. You'll no longer hear your voice once the machine starts to operate. With this problem scientist came up with the thought of innovating the said machine. Silent generators were then invented to ease the problems of many users. Silent generators are a lot of convenient to use compared to the traditional sorts of generators.
How to Weld Sheet Metal Together
03.24.11
Set up direct lighting for the work area. Make sure there are no flammable rags or debris in the area.
Clamp the sections of sheet metal together, with the object being to have as tight and flush of a seam as possible. You may decide to overlap the metal or possibly line it up evenly next to each other. If this is the case be sure to lay a piece of wood under the seam area to be welded. Be sure your metal edges are level using your hammer to pound down any rough edges
Using your sandpaper or wire brush be sure that the areas to be welded are clean, removing any paint or wax. It is imperative that the area be clean metal or the weld may not stick. Your small grinder can be used here too for any tough spots.
Set up your MIG weld settings while the main power is still off. For tack welding 22 gage together I set the welder at minimum power, which is a lower heat setting, and the wire feeder speed at a low setting of around 3. Also attach your grounding clamp somewhere onto the metal, and out of your way
Be sure you have your long sleeves on, heavy gloves, and of course your welding helmet. Run through a test weld before turning the power on, running the tip of the wand along the metal, being sure you will have enough elbow room and space to complete the weld with one easy flow.
Turn the welder on and place the wand on an angle to the spot to be welded and while you are holding the wire feed trigger down, being sure the wire will be touching the seam, move the wand slowly across the area, but not too slow or you will burn a hole in the metal. Too fast will leave you nothing but spatter. This is where you will have to practice to get the feel for your welding speed. A proper weld should leave you a weld spot from the melted metal on the top side with heat penetration through to the other side of the metal.
Using your grinder, carefully level out any welding spatter or high spots so you have a level surface. With 22 gage, which is a thinner metal, apowerful circular grinder can easily burn off your entire weld very quickly. I prefer to use the small grinder attachment on a Dremel tool for more control.
Now you can either fill in any open seams with liquid metal or J-B Weld or continue with a bead style weld pattern to fill in the entire seam, waiting for the metal to cool down between welds.
Tips to Improve Stick Welding on AC and DC
03.22.11
Current setting, Length of arc, Angle of electrode, Manipulation of the electrode and Speed of travel. If you're just learning the Stick process, technically called Shielded Metal Arc Welding, remembering these five points will improve your welding technique.
DC welding offers advantages over AC for most Stick applications, including: easier starts; fewer arc outages and sticking; less spatter/better looking welds; easier vertical up and overhead welding; easier to learn "how to weld" and a smoother arc. DC reverse polarity (electrode positive) provides about 10 percent more penetration at a given amperage than AC, while DC straight polarity (electrode negative) welds thinner metals better.
Ac output has an advantage so if you need to weld on material that's become magnetized from friction, such as when hay, feed or water constantly rub against a steel part. A DC output won't work because of "arc blow," where the magnetic field blows the molten filler metal out of the weld puddle. Because an AC output alternates between polarities, it enables you to weld magnetized parts.A 225 to 300 amp machine handles almost anything the average person will encounter, as most Stick welding procedures require 200 amps or less. To weld material thicker than 3/8 in., simply make multiple passes - this is what professionals do, even when welding on 1 in. structural steel.
IGBT Technology Over Power Mosfet
03.16.11
The Insulated Gate Bipolar Transistor (IGBT) is a minority-carrier device with high input impedance and large bipolar current-carrying capability. Many designers view IGBT as a device with MOS input characteristics and bipolar output characteristic that is a voltage-controlled bipolar device. To make use of the advantages of both Power MOSFET and BJT, the IGBT has been introduced. It’s a functional integration of Power MOSFET and BJT devices in monolithic form. It combines the best attributes of both to achieve optimal device characteristics
The IGBT is suitable for many applications in power electronics, especially in Pulse Width Modulated (PWM) and three-phase drives requiring high dynamic range control and low noise. It also can be used in Uninterruptible Power Supplies (UPS), Switched-Mode Power Supplies (SMPS), and other power circuits requiring high switch repetition rates. IGBT improves dynamic performance and efficiency and reduced the level of audible noise. It is equally suitable in resonant-mode converter circuits. Optimized IGBT is available for both low conduction loss and low switching loss.
The main advantages of IGBT over a Power MOSFET and a BJT are:
1. It has a very low on-state voltage drop due to conductivity modulation and has superior on-state current density. So smaller chip size is possible and the cost can be reduced.
2. Low driving power and a simple drive circuit due to the input MOS gate structure. It canbe easily controlled as compared to current controlled devices (thyristor, BJT) in high voltage and high current applications.
3. Wide SOA. It has superior current conduction capability compared with the bipolar transistor. It also has excellent forward and reverse blocking capabilities.
Plasma Cutting Aluminum
03.10.11
Plasma cutting isn't new. But like any technology, it has its share of new developments. In any discussion about how to cut metal, it's right up there with laser and waterjet. The technology gets a bad rap, though, when the discussion turns to cutting aluminum.
Plasma cutting has been around for decades, but the first plasma cutting machines were crude in terms of both the machine control and drive system, as well as the technology itself. Manufacturers of plasma cutting systems have made improvements to the technology in recent years, but many end users still cut with the old machines or buy machines that don't have the most recent upgrades. As a result, some perceptions of plasma cutting are outdated.
This is an issue of gas selection, Cutting aluminum with air produces a rough edge coated with aluminum oxide. Different gases usually an argon/hydrogen mix make more sense for aluminum. With the proper selection of gases, you can get a very nice edge on aluminum with plasma.
In terms of issues of porosity, [fabricators can] cut aluminum with many different gas combinations, For very thin material, people will often use air/air, and certainly they'll want to look at their edge for welding concerns, but [they also can cut] with fuel gases, which avoid oxidation. And in those cases, you get weld-ready edges. This reduces overburning and allows fabricators to optimize cutting speed versus cutting power.
Many fabricators plasma-cut aluminum very successfully, and there's been a lot of development of aluminum processes using different types of gas, but even cutting with straight air—which is very common—yields great results. For people cutting aluminum plate, such as for military vehicles or trailers or rail cars.
Equipment for welding and Plasma Cutters
03.09.11
There many varieties of welding equipment which are used for different purposes. One of the most important things for these welding and cutting equipments is the water cooler. The work of water cooler is to cool the welding machines which get heated while welding. The welding heats up the torch of welders which needs a supply of water. Apart from these welding equipments you also need a welding helmetwhich protect for eyes and face from any harmful burns or sparks.
Plasma Cutter:
One of the most important things used for any construction is the metal. Metals play a vital role in constructing buildings. Now to cut the metals you need a cutter. There are some cutters which doesn't cut all kind of metal. But there is one cutter which can cut all the metal in no time. It is known as plasma cutter. These cut the metal with the help of plasma torch. These are utilized for cutting steel and all conductive metals. These cutters need high voltage and are epitomized of plasma gas. To make use of this first the plasma gas is created. The advantage of this is it can cut any metal at high speed. While cutting the inner surface remains cool and this does catch fire in any circumstances.
Welders:
You can find many types of welders for welding objects like steel, aluminum and many other metals. Some of the welding equipments are Mig weld or GMAW, Tig weld or GTAW, Stick weld or SMAW, Spot weld and Arc weld. All these have different purpose and used for different industries. You can also find multi purpose unit which consist of plasma cutter, Mig weld, Tig weld and stick weld. They are the most versatile equipment because the space they need is really very less. Buying has made easy by shopping online. Now you can search and learn more about this product on net. Almost all the products have advantages and disadvantages. So buy the equipments which are very useful in your daily life.
Read more at http://www.articlealley.com/article_1645923_45.html?ktrack=kcplink
Read more at http://www.articlealley.com/article_1645923_45.html?ktrack=kcplink
How To Sharpen Tungstens For Tig Welding
03.08.11
Tungsten, the other name for the metal known as wolfram, is known for having the highest melting point of all alloyed metals and the second highest melting point of all elements, lower only than carbon's. These properties make it especially useful for lightbulb filaments, x-ray tubes and other appliances that require high heat resistance. Tungsten is also often used for electrodes in torches. These tungsten electrodes need to be sharpened to achieve the high voltages required to ignite torches.
How to sharpen using a machine:
Clean out the vent of the machine before use. Tungsten dust can clog the machine and prevent sharpening.Place the electrode inside the machine and align the tip of the electrode with the tip of the sharpener. You can align it through a viewing window.Turn on the machine, and turn it off after 30 seconds. Repeat this step until you achieve the desired sharpness.
How to sharpen manually:
Wrap the sand paper around the base of the electrode.
Pull the paper toward the tip of the electrode while gently applying inward pressure. This should be done in one continuous stroke.
Repeat last step until the desired sharpness is reached.
How to Stick Weld Aluminum
03.04.11
An arc welder creates an electrical current through an electrode, which melts the metal to form a weld between two work pieces. In some arc welding processes, the metal in the electrode also melts to make the weld. Arc welding machines may produce an alternating current (AC) or direct (DC) current, depending on the specific application. Aluminum is generally harder to weld than steel, and you'll need to select a welding machine specifically for welding aluminum.
Examine the difficulties of welding with aluminum. This metal conducts heat better than steel and has a lower melting point than steel. This combination of factors means that it's much easier to completely melt the aluminum pieces. Aluminum is also more chemically active than steel.
Select a more powerful welding machine so that you can make the weld more quickly. A 115-volt arc welder can weld aluminum up to 1/8-inch thick and a 230-volt machine can handle aluminum that's up to 1/4-inch thick.Use welding machines that provide a constant current and voltage for spray-arc welding. This type of arc welding uses an arc that sprays a small stream of molten metal from the electrode to the base metal.
Ensure that the contact tips on the electrode feeder are larger than the electrodes. Aluminum expands more than steel in response to heat, and the contact tips will need to be approximately 0.015 inch larger than the electrode.Push the welding gun away from the weld puddle, rather than pulling it towards the weld puddle. This will make the arc less likely to overheat the base metal.You must make aluminum welds much more quickly than steel welds.
Mig Welding Aluminum with a Spool Gun
03.02.11
For Mig Welding aluminum.....You really need a spool gun.For 1/8" thick aluminum, unless you have the machine set just right, the slow steady bead just builds up too much heat because by the time you reach the edge of the metal, its really too hot and leaves a huge crater.
Fine little droplets of metal "spray" into the weld. When you mig weld steel with "short circuit transfer" the wire actually fuses into the puddle and then arcs back many times a second and makes that bacon frying sound.You do not want to hear a bacon frying sound when mig welding aluminum. IF you do, you have too much wire speed.
Another technique that I like better is to use kind of a step and pause technique where you hitch ahead quickly about a quarter inch and then pause...to the tune of about once every second.So it goes like this. move ahead and pause...thousand one...move ahead and pause...thousand two.. This step and pause welding technique puts ripples in the weld like a tig weld. Almost like a stack of dimes. Another benefit is it seems to build up less heat by moving quicker.
MIG welding uses a continuous spool of wire to create a weld bead on metal. The soft nature of aluminum wire causes a MIG welder to jam when the wire travels through the lead of the MIG welder to the MIG gun. To reduce the distance the aluminum wire has to travel, you need to use a spool gun. A spool gun is a self-contained MIG welder that holds a small one pound spool of aluminum wire in the gun, rather than remotely in a MIG welder.
How Pulse Mig Welding Helps You Save
03.01.11
Some of the latest technology power sources on the market today are those that provide pulsing capabilities. Most likely, you have heard how these sophisticated machines make welding easier for the operator and provide a high quality weld. But, did you know that these machines actually provide a cost savings? Although you may pay a little more for these power sources initially, the advantages that they provide will decrease overall welding costs and provide a payback of your investment in the long run.
Wire and gas savings- Pulsed MIG machines offer a wider operating range because they extend the low and high range of each wire diameter. For instance, before the operator would have to stock .035”, .045” and .052” wire diameters for varying applications, but with Pulsed MIG, .045” can be extended on the low end and top end range so that it can be used for a variety of applications. What this means is that rather than having two or three different sized wires, an operator would only require one. Having one wire type minimizes inventory costs and reduces changeover times. The same is true with shielding gas – one gas can reach both the low and high ranges of the application. In addition, the different types of spare parts (gun, gun tips, liners, etc.) are decreased for additional cost savings.
Spatter and fume reduction- Compared to Conventional MIG, Pulsing offers reduced spatter and fume. Reduction in spatter translates into significant cost savings because more of the melted wire is applied to the weld joint, not as surface spatter on the product and surrounding fixtures. This also means less clean-up time. A reduction in the welding fumes creates a safer and healthier environment for the entire plant or shop.
Heat reduction- Pulsing offers controlled heat input leading to less distortion and improved overall quality and appearance which means fewer production problems. This is especially important with stainless, nickel and other alloys that are sensitive to heat input.
Improved productivity- Pulsed MIG offers high deposition rates. In addition, since the new machines are simpler and adaptive, it is easier to weld with pulsed MIG than other transfer methods, less time is spent training.
Better quality- All these advantages of Pulsed MIG outlined above result in overall better quality of the finished and a more stable arc. In addition, operators are receiving a better quality working environment since they are not dealing with fume, spatter and extra clean-up or grinding time. One more benefit is that synergic power sources allow for these high quality welds to be achieved by those with relatively less training.
Tig Welding Aluminum with an old Tig Machine
02.28.11
First you need a decent TIG welding machine. Not a great one, just a decent one. If you have an old as dirt TIG welding machine, you can still make good aluminum TIG welds. Weld beads that look like a stack of dimes.
First lets look at machine settings:
Set the polarity to A/c (alternating currrent)
Make sure to set the high frequency to continuous
Set the amperage to about one and one half amps per one thousandths of inch of thickness. (up to about 250 amps then things change quite a bit)
Set both the contactor and amperage switches to the remote positon.
Set the argon or argon/helium torch shielding gas to around 15 cfh. (if you are using a #7 cup) less if the cup is smaller.
Notice I said argon or argon/helium? Argon is not the only game in town. In fact, if you TIG weld any aluminum over about .063" thick, adding helium to the mix makes a huge difference.
Tungsten electrodes
2% thoriated have received a lot of bad press for the radioactivity issue but they do work.
2% lanthanated electrodes are a really good all purpose electrode...good for TIG welding aluminum as well as steel.
Use the smallest electrode that will get the job done without quivering at max amperage.
Remote amperage control
Once all the settings are ok, and assuming you are welding on 1/8" thick aluminum, grab a piece of 4043 filler rod in 3/32 diameter (rarely will you use a rod as thick or thicker than the metal you are welding)
extend the electrode tip about 1/4" past the tip of the TIG torch cup and pre purge the gas by tapping the foot pedal.
hold the torch like a big first grade pencil. touch the tip of the tungsten to the metal and then pull it back about 1/8 inch. flip your helmet down and press the pedal to initiate the arc.
don't melt the aluminum right away though, watch the black stuff cook away from the arcs cleaning action before you melt the metal. Then press the pedal far enough to create a puddle that is about 3-4 times the thickness of the metal you are welding.
Now comes the part on how to achieve the "stack of dimes" look. You get that by adding the same amount of rod and by moving the torch the same distance each time you add rod. Add rod, Step ahead 1/8 inch,Add rod, Step ahead 1/8 inch,Add rod, Step ahead 1/8 inch, lather rinse repeat. If you do this consistently, you will get evenly spaced ripples that look like a stack of dimes.
Silent Generators
02.25.11
The benefits that these alternative sources of electrical power can offer are out of the question. They can be a real life saver if power failure occurs and the need to make a major electronic equipment function is absolutely necessary. If you live in an area where power interruption is as constant as 3.14, you may be plagued by the sound of generators that you and your neighbors use during these outages. Imagine using silent generators instead? It will not only provide power but can also be a great stress reliever as you do not only have electricity but silence as well.
The noise that a regular generator produces is definitely not pleasing to the ear, which is a sad reality for generators. While the light that they give can make the eye pleased, the noise that they produce annoys the ears. This is why many people prefer silent LONGEVITY generators to avoid the deafening sound that its noisy counterparts produce. These types of LONGEVITY generators are a perfect solution to the problem of noise that regular generator give out. This is possible as the materials used in manufacturing silent generators effectively prevent the reverberation of the noise that its mechanism causes.
Silent generators can be used in both residential and commercial areas. Any place where a regular generator is used, the silent generator can also be used. Whether it is a hospital, a business area or a home, generators that produce no noise can be used. To put it simply anywhere the owner wants the silent generators to be installed, no doubt it can be done.
TIG WELDING BASICS
02.23.11
Tungsten Inert Gas (TIG) welding is a basically a welding process that works with the help of a tungsten electrode. The electrode is used to produce the weld and a shielded gas, like argon, protects the weld area from atmospheric contamination. The electric power for welding is provided by a constant current power supply. The basic TIG welding process was initially named Heliarc, as helium was used when it was invented. Proper cleaning of the weld joint area and the filler metal is necessary for the removal of oil, grease, dirt, paint, etc. Such contaminants may result in arc instability and a poor weld.
The knowledge of TIG welding basics is useful for the welding of almost any metal. The process can be used to weld Stainless steels like 304 and 321, 1010 carbon steel, Nickel alloys, Aluminum alloys like 6061 and 5052, Titanium alloys like 6al4v, Copper alloys like Nibral bronze, etc. The power source should be AC / DC welder with a high duty cycle and a high frequency. The high frequency feature enables the stability of the arc during zero voltage conditions in the alternating current cycle.
With technological advancements in the field of power source, the use of pure tungsten has decreased. The main reason for this is the low melting temperature of tungsten, which causes the formation of a rounded ball at the tip. With the growth of the ball, it becomes more difficult to see the weld puddle, causing instability of the arc. Ceriated tungsten provides a better alternative because of its ability to withstand higher temperatures. It can also be used on both AC and DC polarities and it increases the welding amperages by 25 to 30 percent as compared to pure tungsten. Thoriated tungsten is also available in the market and is popular for its higher current capacity. It also allows easier arc starting and greater arc stability for the basic TIG welding.
The most important component of TIG welding is the TIG torch, which delivers electric current and shielding gas to the weld joint. There is a huge variety of torches available in the market. One should use a torch that fits comfortably in one's hand and stays cool. Air cooled and water cooled torches are also available for TIG welding. Air cooled torches, which are rated at 150 percent of the welder's rating, serve a good purpose. Water cooled torches are good for professionals but are impractical for the hobbyist. The filler metals used in TIG welding are categorized in a similar way as Arc Welding electrodes. Commonly these filler rods are 36" long and their diameters are available in 1/16, 3/32 and 1/8 diameters. Oxy-acetylene welding rods are not compatible with the TIG welding characteristics.
It is advisable to use tungsten of the smallest possible diameter and match the size of the electrode with that of the collet. Premium quality torch and work leads should be used, and while welding, they should be kept as short as possible. Before welding, one should also ensure that the Stick electrode holder is detached from the machine.
3 PHASE POWER
02.22.11
Three-phase is a common method of alternating-current electric power generation, transmission, and distribution. It is a type of poly-phase system and is the most common method used by grids worldwide to transfer power. It is also used to power large motors and other large loads. A three-phase system is generally more economical than others because it uses less conductor material to transmit electric power than equivalent single-phase or two-phase systems at the same voltage.
In a three-phase system, three circuit conductors carry three alternating currents (of the same frequency) which reach their instantaneous peak values at different times. Taking one conductor as the reference, the other two currents are delayed in time by one-third and two-thirds of one cycle of the electric current. This delay between phases has the effect of giving constant power transfer over each cycle of the current and also makes it possible to produce a rotating magnetic field in an electric motor.
Three-phase systems may have a neutral wire. A neutral wire allows the three-phase system to use a higher voltage while still supporting lower-voltage single-phase appliances. In high-voltage distribution situations, it is common not to have a neutral wire as the loads can simply be connected between phases (called phase-phase connection).
The phase currents tend to cancel out one another, summing to zero in the case of a linear balanced load. This makes it possible to eliminate or reduce the size of the neutral conductor; all the phase conductors carry the same current and so can be the same size, for a balanced load.Power transfer into a linear balanced load is constant, which helps to reduce generator and motor vibrations.Three-phase systems can produce a magnetic field that rotates in a specified direction, which simplifies the design of electric motors.
Most household loads are single-phase. In North America and some other countries, three-phase power generally does not enter homes. Even in areas where it does, it is typically split out at the main distribution board and the individual loads are fed from a single phase. Sometimes it is used to power electric stoves and electric clothes dryers.
Dual Voltage Multi Purpose Units
02.18.11
We have got brand new dual voltage multi-purpose machines in stock. Dual voltage is important because not all people have a 110v and 220v breaker in their home or business. To have a multi-purpose unit that is dual voltage is important because it will help the customer save money and not having to buy a Plasma Cutter and a Tig,Stick, or Mig Welder separately to use these functions.
Dualvoltage is a term used to describe any type of electronic device that is manufactured to recognize and use both American and European currents without the need for an additional transformer. The conversion is completed internally within the item, So LONGEVITY machines with dual-voltage the customer does not have to worry about where they will or will not work—however, a plug-in adaptor may be required to use the item outside the country of origin and ensure proper safety. standard.
Overhead Welding
02.17.11
OVERHEAD POSITION WELDING
Overhead welding is the most difficult position inwelding. Not only do you have to contend with the forceof gravity but the majority of the time you also have to assume an awkward stance. Nevertheless, with practiceit is possible to make welds equal to those made in theother positions.Current Settings and Electrode Movementto retain complete control of the molten puddle, usea very short arc and reduce the amperage as recommended. As in the vertical position of welding, gravitycauses the molten metal to drop or sag from the plate.When too long an arc is held, the transfer of metal from the electrode to the base metal becomes increasinglydifficult, and the chances of large globules of moltenmetal dropping from the electrode increase.
When you routinely shorten and lengthen the arc, the dropping ofmolten metal can be prevented; however, you will defeatyour purpose should you carry too large a pool of moltenmetal in the weld.One of the problems encountered in overhead welding is the weight of the cable. To reduce arm and wristfatigue, drape the cable over your shoulder when welding in the standing position.
Tig Welding Techniques
02.16.11
TIG Welding Techniques
The different techniques of TIG welding mentioned below are used for different industrial applications. A brief account of three TIG welding techniques, the pulse-current, dabber, and hot wire is given below.
Dabber: This technique is used to increase the accuracy of welding. In this method, a cold filler wire is used for feeding, and it is dabbed or oscillated into the welding area. This method is used for welding nickel, titanium, tool steels and various alloys. Milling cutters, seals in jet engines, mower blades, and drill bits are the common applications where the dabber technique is used.
Pulsed-current: In the pulsed-current technique, the current used in welding alternates between two levels, i.e. the pulse and background current. The pulse-current denotes a higher current while the background current means a lower current. In the pulsed-current technique of welding, the weld area gets heated and the fusion takes places during the pulse-current or higher current period. During the period of lower or background current, the weld area solidifies due to cooling. Some of the advantages of using the pulsed-current method is that the amount of distortion in welding is reduced considerably. Weld speed and weld penetration increases, while the quality of welding is improved if this technique is used.
Hot Wire: The hot wire technique of welding is slightly different than the above mentioned techniques. In this method, filler metal to be added during welding is 'resistance heated'. The heating is done till the filler metal reaches its melting point. The deposition rate of the machine is increased because of prior heating of the filler metal.
The process of TIG welding is a type of arc welding. Unlike the MIG welding techniques that are easy to learn, TIG is difficult to carry out. Professionals or experts are required to successfully carry out the process. The above article provides information regarding the basics of TIG welding and various TIG welding techniques in short.
The Differnece between Aluminum And Steel
02.14.11
Aluminum is a low density metal that is often used because of its innate ability to resist all sorts of corrosion. It is often used in the construction of buildings, Welding, transport vehicles as well as in the aerospace industry where many structural components have aluminum and its alloys as bases. It is lightweight, soft yet durable, malleable and ductile. Its appearance can range from something silvery to those that carry a duller gray tinge to it. This depends upon the roughness of its surface.
Some of the latest technology power sources on the market today are those that provide pulsing capabilities. Most likely, you have heard how these sophisticated machines make welding easier for the operator and provide a high quality weld. But, did you know that these machines actually provide a cost savings? Although you may pay a little more for these power sources initially, the advantages that they provide will decrease overall welding costs and provide a payback of your investment in the long run.
