Posted: February 11, 2019|
Becoming a commercial welder is what many people want, however there are yet much more people that would be good at that profession and yet they do not know it yet. Welding is being taught at schools and special courses and those young men that want to make a career in commercial welding or industrial welding first have to earn a structural welding certificate and be taken on the construction site or in the field.
Welding is a profession that is paid well, gives the workers a lot of freedom and has many advantages which appeal to those people who do not see themselves working from nine until five for five days in the week. At the same time learning how to weld and be good at that is not easy and the job is associated with a lot of risk and dangers.
The welders can work on many sites including repair shops, black iron plants, fields, etc. They will be better off in case they have joined the International Association of Bridge Structural, Ornamental and Re-Enforcing Ir
Welding industry has its specific welding terms that each commercial welder has to be aware of. Of course, there is no need learning the entire welding vocabulary, yet one should get acquainted with some of the major terms, such as:
Arc Cutting – process that can be done with a 6010 or 6011 rod with a very hot machine. It is where you cut through the steel using the force of the arc.
Automatic Welding - a weld made by special equipment.
Flash Burn - This is a radiation burn from the ultra violet rays from the welding arc. The flash burn is similar to sunburn and it starts hurting hours later, being very painful to the eyes.
Machine Welding – the weld is done by machine and is inspected by a person.
Manual Welding – welding by an actual person. In stick welding, the welder holds the stinger, processing the welding electrode and controlling the we
Known as GTAW process, as the commercial welders call it, the gas tungsten arc welding process was created back in the 1940s when it was necessary for aluminum and magnesium alloys to be welded for the use of the aircraft industry and applications.
The gas tungsten arc welding process was developed as a new method of welding as it was necessary for welding to be done on these materials in a better way than the SMAW or the shielded metal arc welding process. Nowadays, the commercial welders are using the GTAW welding process when they have to weld precision parts such as metal bellows, batteries, various medical components, pacemakers, different surgical tools, etc.
In the beginning, the commercial welders were using the helium as the shielding gas and thus they named the welding process ‘heliarc welding’. Then the helium was replaced by the argon, which bec
If you follow the best design, then joining of the thick parts to the thin ones should be as less as possible. In situations where we have no option but to attach the thick to the thin, there are certain basic rules that have to be kept in mind for it to be a success. The part that is thicker will always be capable of absorbing more of the heat than the part that is thinner.
The thermal conductivity of the metal and their after effects on the process of welding should also be taken into account. A metal like Aluminum is capable of absorbing a lot more heat than metals like stainless steel or steel. In the process of welding a thick metal to a thin one, we have to pay attention to the correct setting of the amperage lest we burn the thinner metal in the welding process – if the level of amperage setting is adjusted to low so that we can avoid excess melting, the heat may not be sufficient to melt the thicker part and similarly,
if the level of amperage setting i
Most of the commercial welders are well trained in order to pass the welding tests, however there are newbies that would benefit from some tips on how to handle the situation. In general, the UA-28 pipe welding test represents a 6 inch schedule 80 pipe,
which is being done in a 6g position by using a 6010 for root pass and also a 7018 fill and cap. With the test spec, the welding test for UA-28 pipe, required 0-1/8"" land (0-3mm), while the required1/16"" to 1/8"" gap (1.6-3mm) , and with a 1/16"" (1.6mm) maximum mismatch, and a 75-100 amp range for the 6010 1/8"" (3mm) of the electrode root pass. With that test, like almost all welding tests, the difference is made by a fit up. How is this so? Let us set an example.
The tight gap requires the usage of more amperage by the commercial welder and the wider gap requires less amperage to be used. Exactly the same goes for the land... When there is a heavy 1/8"" land, this allows the commercial welder to use more
What a metal looks like inside, at the atomic scale, has a great influence on its reaction to heat applied to it during the process of welding and cutting. The arrangement and location of the atoms is so small they cannot be seen even through the world's most powerful microscopes, yet these arrangements are responsible for most of its material properties. Strength is the main material property compromised from the heat of welding, but there are others as discussed in previous articles.
Materials can exist in four different states of matter. Solids, liquids, gases and plasmas are the four states of matter that materials on this earth can exist as. Metals are made from crystalline structures that are definite in pattern and shape. Each metal has its own crystal structure, but most metals are made from four predominant types. Body Centered Cubic (BCC), Face Centered Cubic (FCC), Hexagonal Close Packed (HCP) and Body Centered Tetragonal (BCT). Each me
Commercial welders use one very smart way to identify metals and this method is called spark check with a grinder. There are well organized spark charts in the text books and in various websites where the sparks from the test can be compared. Some commercial welders also use the magnet test and yet others use the puddle test with a TIG torch.
There are various factors that can affect the decision of the commercial welders when it comes to metals and especially when they have to perform TIG welding on cast iron metals. The main question here seems to be which is the right filler rod for the cast iron. The high nickel rods that are sometimes used comprise of nickel mainly and are expensive. The NI rods show great compatibility with TIG welding cast iron. The nickel rods are very good at that as the nickel absorbs the carbon and iron but is still ductile.
Commercial welders further say t
Commercial welders know that the tungsten electrode charts come with a list ranging for q 2.4 mm, ceriated, lanthanated or thoriated electrode which is around 150 and 250 amps. Yet many commercial welders use the tungsten electrodes at lower amperages and have no issues with that. The 3 /32 ‘’ tungsten electrode or is it possible to do TIG welding with thin sheet metal? A professional commercial welder will tell you that if you want to perform TIG welding on very thin metal, the electrode must be tapered like a needle. In such cases one should use a fine grit disc, a sanding belt or a diamond wheel.
In such cases one should avoid the scratches that are running sideways. The commercial welder can start the TIG welding process at high amperage or can get a crisp start. If the application is pipe welding, then one might use a scratch start TIG setup. Many pipe welders use the 1 / 8’’ electrode even in cases when the amperages are around 100 amps. Then the material is thinner
There are many welding processes that apply power supply and which are presented in this article. One of the most popular welding processes that commercial welders perform these days and which had great usage in the past decades is the arc spot welding. The advantage of this type of welding is the ability of the commercial welder to spot weld from one side of the work. Moreover, this is a very fast welding method for the production of multiple spot welds with a high degree of reproducibility.
MIG welders know that the arc spot welding can be done by using gas shielded metal arc processes and tungsten inert gas. When the multiprocess welder performs tungsten spot welding, one uses the same power supply that is required when performing regular TIG welding process. In this case however, the commercial welder requires special spot welding gun and controls. During the TIG spot welding there is a fusion of the parent metal and no filler wire is used. As a rule, the commercial w
Commercial welders often say that steel includes many different types of metals that are made of iron. Approximately 85 % of the metal that is produced is steel. In general, steel is the alloy of iron and carbon. However, steels often contain other metals as well including nickel and chromium, as well as manganese, as well as different nonmetals such as silicon and carbon sulfur and phosphorus.
Multiprocess welders confirm that there are various kinds of steels and sometimes even they are confused to identify the steel that is used. For example, steels could be stainless steels and structural steels, hot rolled steels, and reinforcing steels, low alloy high strength steel, cast steels, tool steels, etc. On some occasions steels are named after the main ally they have, as for example chrome-molybdenum steel, chrome-manganese steel and carbon steel.