Welding is not an easy job and every commercial welder will confirm you that. The welding tasks, no matter if they require usage of filler rods, tig welders or plasma cutters, stick welder or plasma welder they all require full commitment of the energy, attention and focus.
This means that the welder should be 100 % concentrated in the task one performs and to make his or hers hand and wrist totally relaxed. Of course everything comes with practice and that is why the new people in the welding profession require not only a welding certificate taken after two years of study, but also a lot of hours actually welding different things and practicing.
The good commercial welders know that in order to become true professionals they need to make their hand relaxed and to watch the weld pool. This is especially important when performing mig welding but is also valid when practicing aluminum welding, cutting torch, metal cutting and metal welding, steel welding, etc.
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
Every commercial welder will tell you that the arc length, also called arc gap, is the distance between the part that has to be welded and the electrode tip. The arc length depends on the arc stability, the weld current and the concentricity of the part. The task of the commercial welder here is to keep the electrode at a certain distance from the surface so that there is enough place to avoid stubbing out. In general, the arc length is 0.10 inch and this measurement is taken as a base. One half of the weld penetration is combined with the base measurement and this results in the arc length for a certain amperage.
The weld speed that the commercial welder has to choose is the speed of travel of the torch ad it is dependent on the flow rate of the material that has to be welded and also on the thickness of the material that needs to be welded. In general the commercial welders should weld as quic
Often the multiprocess welders have to weld ad work on stainless steels. The stainless steels, also known as steels that resist on corrosion are part of the iron-base alloys. As commercial welders know, these steels do not rust and have high resistance on the attacks of chemicals, gases and liquids. Most of the stainless steels come with good ductility and low-temperature toughness. MIG welders, Arc welders, TIG welders, and Stick welders, further say that these steels are resistant to high temperatures and show good strength properties. As a rule, the stainless steels contain iron and chromium, which could be varying from 11 to 30 %. It is the chromium that secures the basic corrosion resistance of the stainless steels. In general, there are almost 15 different types of chromium stainless steels.
The commercial welders know that to certain stainless steels is added nickel. These steels are known as chromium-nickel stainless steel. Due to the nickel, the thermal conductiv
Every time we weld on a piece of metal or even heat it up with a torch, the shape of the metal changes as we apply thermal energy or heat. The metal expands based upon a physical property called the coefficient of thermal expansion. This coefficient is different for each metal and is described in a unit that tells us how much the material grows per degree of temperature increase, or contracts when cooling. There are also other factors that contribute to distortion such that the temperature increase may remain localized close to where the weld is made, but other materials may spread out the heat far from where the weld is being made warming up the entire part or unit. How much restraint or bracing is there to support the part can also be a factor too. How much heat also plays a role. A careful selection of welding process will also play a big factor.
If we look at the most simple case of distortion, it can be easier to understand. Imagine a flat st
Leather gloves are necessary for a welder. There is a huge collection in the market now but be cautious, a few have a “one-size fits-all” design that will feel inconvenient and distressing. Devised by welders for welders, longevities Arc -armor safety equipment comprises of form-fitted gloves, jackets and adornments.
It is sensibly alluring, when you are in a hurry to get a project accomplished, to disregard appropriate safety formalities and ingenuously catch hold of your welding gear to lay down a quick bead. You might get off without any harm at times, but that time when you do not prefer wearing a welding jacket and a fragment of spatter burns a cavity through your shirt or it might as well burn your skin, you will regret your decision of not wearing welding jacket as a precaution.
The basic thing to remember about welding safety is that the suggested clothing and strategies exist for a reason- because welding, if not done properly might be dangerous. When
Various attributes of the weld may be analyzed during a welding evaluation, some about the weld dimensions and others about the use of discontinuities of the weld. The dimension a weld may take is crucial since it can directly associate to the weld’s durability and associated efficiency, small welds may not hold up against pressures applied while in service.
Discontinuities of a weld may also be essential. These are blemishes with or close with the weld, that can or not relate to their dimension and/or place, obstruct a weld from conference its designed efficiency. Generally, such discontinuities, when are of undesirable dimension or place, are called welding problems and can also sometimes cause early weld failing though the lessening of the weld’s durability or though generating stress levels within the element of the weld.
The evaluation of the welds may be carried out for numerous reasons. The most basic purpose is to decide if the weld has a suitable and t
Getting Familiar with Your Welder
You should get familiar with the feel of the gun and familiarize yourself with the effects of changing things like current and wire speed before you try any actual welding. You should start your practice using a common grade of carbon steel like A36, which is the most commonly used steel in manufacturing heavy equipment and readily available as scrap at most industrial equipment manufacturers.
Try to find a piece that is about the same thickness as the steel in your work project so that you can get a feel for penetration without blowing holes through the piece. You will also want some thinner and thicker practice pieces as well to experiment with current and wire feed settings.
Start with a piece that is about 3.0 mm thick so that you don't have to worry about blowing holes through the piece if you linger a litt
When do we Inspect the Welding?
What is the ideal time to inspect a welding? Inspection is most crucial in any welding procedure, having an idea of when to inspect, what to lookout for and the criteria that is acceptable for a particular code or specification. These are just a few things that we have to keep in mind at the time of inspecting a weld and has to be done prior to, in the course of and at the end of a welding process. There are some things that have to be checked before welding commences. For instance, we have to ensure that we have prepared the metal which has to be weld properly and following all the drawings.
In case there is a specification for the welding process, we have to see that the configuration of the joint and the material prep is in compliance with that of the document. It is important to check the material and see that it both clean and free from any grease, oil, paint or rust or other surface impurities and other res