Welder World Blog

Archive for July, 2010

Video discusses welding in the high school metal shop. Part of the metalwork curriculum these this vdo gives tips to successful welding. Our shop has a hobart 135 handler and a Miller 251. We also have tig and stick capabilities.

Emergency welding technique using 3 car batteries wired in series. Knowing how to do this may just save you from haivng to leave your rig out in the middle of nowhere. If you’re going to go wheeling you need to know how to save your own butt. AAA doesn’t respond if your 20 miles off the beaten path. This is the second video that I’ve done on this subject. The first video showed me doing an acutal trail repair, but wasn’t very detailed. I had so many responses from people that didn’t understand what was going on, or for some reason thought it wasn’t possible, that I decided to do a video in a controlled environment and show exactly what welding with car batteries is all about.

• Includes ground cable with clamp, welding gun, spool of flux cored wire, face shield and brush hammer
• Thermal overaload protection, 80-125 Amps, Duty cycle 20% at 80 Amps
• Wire size: .030-.035, Heating settings: two
• Max metal thickness: 18 guage / 3/16 inch
• For small to medium sized welding jobs around the home, garage or farm, welds all types of carbon steel.

Product Description
mfr: New Buffalo Corp.
• Welds All Types Of Carbon Steel
• For Small To Medium Sized Welding Jobs Around The Home, Garage, Or Farm
• Includes Ground Cable With Clamp, Welding Gun, Spool Of Flux Cored Wire, Face Shield & Brush Hammer

Features
• Thermal Overload Protection
• Amps: 80 (Max 125)
• Duty Cycle 20%@80 AMPS
• Wire Size: .030 – .035
• Heat Settings: Two
• MAX Metal Thickness: 18 Gauge / 3/16″

Pro-Series MMIG125 125 Amp Fluxcore MIG Welder Kit

now its drivable again.

Product Description
Welding Metallurgy and Weldability of Stainless Steels, the first book in over twenty years to address welding metallurgy and weldability issues associated with stainless steel, offers the most up-to-date and comprehensive treatment of these topics currently available. The authors emphasize fundamental metallurgical principles governing microstructure evolution and property development of stainless steels, including martensistic, ferric, austenitic, duplex, and precipitation hardening grades. They present a logical and well-organized look at the history, evolution, and primary uses of each stainless steel, including detailed descriptions of the associated weldability issues.

Welding Metallurgy and Weldability of Stainless Steels

Hello,

Welding can be a very safe thing to do.  You do however need to know
a few different safety tips before you get started.

Welding Safety General
Welding is a very difficult and dangerous profession so it is
important for each welder to make sure they follow general safety
guidelines. In this way, you can insure not only your safety but
the safety of others around you.

There are a variety of hazards that a welder will face under the
normal performance of their job. Here we list a few of the hazards
you may encounter and what you can do to protect yourself.

Electric Shock
Most welders will have to deal with some form of electric shock
throughout the time that they weld. Although you can take
precautions to keep you as safe as possible, this can happen even
when you are careful.

What to do: Make sure that you weld in an area that is free of wet
areas and outlets that are faulty. Use gloves where practical when
you are using the torch and make sure that you are grounded by
standing on rubber or wearing boots that are shock resistant. Do
not touch electrical parts, including electrodes, with your bare
hands.

Fumes and gases
Most welding by the nature of the way the process works will create
noxious gases and toxic fumes. This is something that is necessary
for the process to do what it is supposed to do.

What to do: Make sure that the area is well ventilated where you
will work and make sure that you weld in an open space. Areas that
are confined make it easier to inhale the fumes and gases, which
can cause the welder to pass out.

Welding Sparks
Welding sparks are a fire hazard but they are a necessary part of
the job because it is the nature of how a welding torch works when
it hits metal.

What to do: make sure that you weld in an area that is free of
debris or materials that can cause a fire. Keep a fire extinguisher
nearby just in case. Wear clothing that is fire retardant, and do
not weld around container that had flammable material in them.

Arc Rays
In arc welding, the arc rays can actually burn the welder’s eyes
and skin if they get near them. It is a good idea to make sure you
wear safety equipment for any of these jobs.

What to do: make sure you have a comfortable filter lens and when
welding, always use a helmet. Make sure the clothes you wear are
fire retardant and that you protect your skin. Also, if you are
working around others, make sure you put up a non-flammable shield
in the area where you are working.

Hazards in general work area
There can be many hazards in your general work area that you may
not be aware of because you may not be conscious of the problem.
Make sure the area is clear of clutter.

What to do: clean up the area; make sure any debris or clutter that
could catch on fire is removed. Make sure any materials or tools
and cables are organized neatly. Make sure your equipment is
grounded or insulated well.

___________________________________________________________________
___________________________________________________________________

Here is a link to a Web Page that covers this email:
http://www.welderworld.com/personal-protective-equipment/2

Have a good one,
Ivan Irons
WelderWorld.com

P.S.
There is more…If you sign up as a member of Welder World Community, you
will get special access to 2 Free eBooks on the site. The eBooks
are about Welding Basics.  Here is the best part, becoming a member is Free!

Wait…The Welding Basics eBooks are Free!
Yes!

What do I get out of it you ask?  A bunch of like-minded Welders and Metal Working Friends
around the world!

Sign Up Now to get all these Welding Benefits!
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Hello,

Today we go over some tips if you are interested in buying a welder.
What to look for, what to think about, what will matter to you when
you get it home.

What to Look for When Buying a Welder
There are so many welders on the market it can be confusing to the
average person as to which one to buy. For the most part, what you
buy will be determined by the kind of project you will be doing
most of the time.

If you are new to welding your first welder will probably be a
stick or a wire feed welder because they are the easiest to use. A
wire welder sometimes is easier because you will use a continuous
feed into your gun as you continue to weld. In a stick welder,
you’ll need to change the electrode or “stick” periodically as it
runs out. Also, the wire welder will be easier to use, give you
better welds from the beginning and you can learn it relatively
quicker than stick welding.

The next thing you will have to decide is the type of welding you
will do most of the time. Generally there are two types: Either Gas
Metal Arc Welding (MIG) or flux cored wire welding. These two are
very different in their delivery so it is important to know the
difference between the two. When you are going to be doing welding
for small repairs, you probably will want to get an MIG welder
because it is very versatile in the types of materials it can weld.

If you are going to use it in your garage at home or the same
location, the MIG welder will be perfect. It is not very portable
because you have to also use a container of shielding gas with it.
If you are going to do a lot of outside welding, then you will
probably want to use the flux cored wired welding. Since flux is
already in your machine, you won’t need a shielding gas and this
makes it more portable.  The only problem is that with this type of
welder, you can only weld one type of steel.

Another idea is to go online and check out the many welding forums
and ask about the various welders. You can read archives and ask
specific questions about your needs, and receive guidance from
other welders.

If you buy your welder through an industrial products manufacture
you may find a welder that does both.

When you buy your welder it is also important to make sure you
purchase the safety equipment need. For some you will need a full
safety helmet and for others you will need at least safety goggles.
However, you can be exposed to fumes, arcs that go haywire,
electric shock and other hazards so you will want to make sure that
you have what you need.

Other ideas for getting the welder you need include renting or
buying used. In some situations either of these options can be a
good idea. If you are only going to use a welder occasionally, you
might consider renting one. If you are going to purchase a used
one, it is a good idea to go with upper end purchases because they
are made better than the cheaper models.

___________________________________________________________________
___________________________________________________________________

Here is a link to a Web Page that covers this email:
http://www.WelderWorld.com

Have a good one,
Ivan Irons
WelderWorld.com

P.S.
There is more…If you sign up as a member of Welder World Community, you
will get special access to 2 Free eBooks on the site. The eBooks
are about Welding Basics.  Here is the best part, becoming a member is Free!

Wait…The Welding Basics eBooks are Free!
Yes!

What do I get out of it you ask?  A bunch of like-minded Welders and Metal Working Friends
around the world!

Sign Up Now to get all these Welding Benefits!
http://www.welderworld.com/index.php?option=com_comprofiler&task=registers

Hello,

MIG Welding is the other main type of welding done today.  Today we
explore it in depth.

MIG(GMAW) or Wire Feed Welding Process Overview
This process is called by many names and it basically is a welding
process that uses an arc to heat metal that needs to be joined. The
welder uses a continuous feed filler metal (a consumable) electrode
and this is used on the work-piece. This type of welding also must
use a shielding that is provided by a gas or a mixture of gasses.

This type of welding is also called short circuit transfer. In the
MIG process, when the wire actually touches the metal to be
connected, it lets go of the metal that does the welding. This
makes sure that metal doesn’t transfer across an arc so there is no
puddling.

Also known as gas metal arc welding, the MIG(GMAW) process uses a
metal gun to provide this service instead of a torch so that you
get a direct current going to the metal. You can use both constant
current and alternating current systems to also produce this method
of welding.

GMAW uses four ways to transfer metal. These are:

Globular — this method is difficult and used the least because it
has a tendency to spatter because the gun will move to a high heat
without warning. This makes the welding surface come out with
flaws.  This method uses carbon dioxide so the electrode tends to
produce a ball of melted metal that cases irregular shapes that are
bigger than the electrode. They then drop and falls onto the piece
you are working on which causes a spatter. This is difficult to
control as you would imagine.

Short circuiting — this uses a smaller current than the globular
method but it still uses carbon dioxide. Because of the lower
current you can actually weld thinner metals together with this
method. This method is similar to the globular method because drops
of melted metal from the electrode still forms, but it causes the
electrode to short circuit instead of the drops falling on the
work. This closes off the arc but comes back again because the
surface tension pulls the metal goblet from the tip.

Spray — this was the first method for transfer used with GMAW and
used to weld aluminium and stainless steel. The difference with
this process is that the electrode metal passes through an electric
arc that is stable and goes all the way to the workplace. This
stops spattering and you get a weld finish that is higher quality
than in other methods. You also will watch as the current and
voltage increases so you get small, vaporized steam droplets
instead of large globules.

Pulse spray — this last one is a newer way of doing this type of
welding that uses a continuous current that pulses and melts the
filler wire. In each pulse a small droplet of metal will fall.

This also allows the welder to use a lower current. The welder gets
a more stable arc and this stops spatter and the short circuiting
process. Because this process is slower, argon gas is used instead
of carbon dioxide as the shielding gas.

___________________________________________________________________
___________________________________________________________________

Here is a link to a Web Page that covers this email:
http://www.welderworld.com/mig-welding-general/2

Have a good one,
Ivan Irons
WelderWorld.com

P.S.
There is more…If you sign up as a member of Welder World Community, you
will get special access to 2 Free eBooks on the site. The eBooks
are about Welding Basics.  Here is the best part, becoming a member is Free!

Wait…The Welding Basics eBooks are Free?
Yes!

What do I get out of it you ask?  A bunch of like-minded Welders and Metal Working Friends
around the world!

Sign Up Now to get all these Welding Benefits!
http://www.welderworld.com/index.php?option=com_comprofiler&task=registers

Hello,

TIG Welding is one of the 2 Most Used types of Welding.  Today we
look at it in depth.  We check out the process and pick up some tips.

TIG(GTAW) Welding Process Overview
The acronym TIG stands for Tungsten Inert Gas Arc Welding and the
acronym GTAW stands for Gas Tungsten Arc Welding this is the same
process but it is referred to by these two different names.

In the situation you will be welding using an electric arc that
generates the heat. You then have a tungsten non-consumable
electrode that then produces the weld you are attempting to make.

One of the things that have to happen in this type of welding is
that the particular metal that you are welding has to be shielded
from contamination in the atmosphere or you will get a poor weld.
Because of this, the area is shielded using an inert gas like
argon; this is used with a filler metal where necessary.

This type of welding needs constant current to flow across the arc
using an ionized gas called plasma. Plasma also has metal vapours
within it. You will usually use GTAW if you have to weld thin
metals like stainless steel, aluminium, magnesium or copper allows.
GTAW also gives the person who is operating the welding process
more control of the weld.

What this means to the weld is that it is a stronger weld and has a
higher quality than many other types of welding. Many experts say
that it is harder to learn, is complex and can be slower than other
welding techniques.

Some welders like using a different kind of torch to produce plasma
arc welding which is very much like this one but a little
different. This type of welding will give a more focused welding
arc, but usually this is done through automation.

How It Operates
The reason this welding process is the most complicated or
difficult to master is because the welder has to use a smaller arc
length; they have to be able to have a very steady hand. If they
aren’t able to keep a distance between the electrode and the piece
they are working on, the piece can become contaminated and there
can be problems with the weld.

This is also a two handed process because you have to be able to
hold the torch in one hand and feed a filler metal into the space
that you are welding. You can see that this is a very intricate
process and one that requires high skill.

There are a few types of welding that will not require this type of
weld and the individual will not have to use filler material these
types include: edge, corner and butt joints. These types of welds
are called autogenous or fusion welds (Source: Wikipedia).

A welder who is highly skilled in this process is able to alternate
between using the torch and then using the filler material in a
pretty fast way.  As they do this the filler rod can be taken out
as the electrode moves forward, and it doesn’t have to be taken out
of the gas shied. This is a highly developed process for those who
can do it well.

GTAW can operate using several different currents: positive direct
current, negative direct current or alternating current. This will
all depend on how they set up the power supply in the beginning.

___________________________________________________________________
___________________________________________________________________

Here is a link to a Web Page that covers this first email:
http://www.WelderWorld.com

Have a good one,
Ivan Irons
WelderWorld.com

P.S.
There is more…If you sign up as a member of Welder World Community, you
will get special access to 2 Free eBooks on the site. The eBooks
are about Welding Basics.  Here is the best part, becoming a member is Free!

Wait…The Welding Basics eBooks are Free!
Yes!

What do I get out of it you ask?  A bunch of like-minded Welders and Metal Working Friends
around the world!

Sign Up Now to get all these Welding Benefits!
http://www.welderworld.com/index.php?option=com_comprofiler&task=registers

Hello,

There are a number of different types of welding.  Today we look over
a few of them.  Depending on what you want to weld, one of these
types will suit you.

Types of Welding
When you think about welding you might think that there is only one
type of welding. This is a common idea because most people only see
the finished product. However, there are many different types of
welding that you might find interesting.

Welding is a way of joining metals to each other to make them firm
and the metal forms a bond that is tight. There are a variety of
bonds that are done depending on the types of welding you use.

Types of welding fit under categories as listed here:

Gas welding
This type of welding creates a flame from a burning gas and this
creates the welding heat that is needed. You will see this in the
following types of welding:

Propane torches — people use this when they want to sweat a joint
or when they want to solder two pieces of metal together. This is
one of the lowest heats and can be used for small things.

Oxyacetylene torch– this heat gets a bit hotter and many people
say this is the most universal type of welding tool you can find.
This is used when you need a very hot flame. This type of torch
will weld a variety of things as long as you have the right metals
and tools for it. It is generally used when you want to cut, braze,
weld or solder something that requires a higher heat. You have to
be careful though because it is a type of heat that can be
difficult to control and it can sometimes overheat the area.

Oxy-propane — this type of welding is used when you want to
solder, braze or heat something. This is a cheaper form of both of
the types of welding that was first listed.

Arc welding
This type of welding creates the heat through the use of an
electric arc. The types of welding that are done through this type
of welding include:

Basic AC & DC arc welders — when you are looking for a way to weld
either heavy gauge steel or cast iron this is the type of welding
to use. It uses rods that you guide along the place to be weld and
these are made of flux coated steel or other materials.

MIG (Metal Inert Gas) — this is a very quick way of welding and
some say it is easier to do than regular arch welding. It is done
through the use of a DC arc and it uses filler metal that is used
with a spool of thin wire. You use inert gas instead of flux. This
is usually used with steal bodywork and is a good choice when you
need to weld sheet metal.

TIG (Tungsten Inert Gas) — this type of welding uses an AC arc
that is of high frequency and it is combined with a tungsten
electrode that is shielded by inert gas. This comes together to
create a torch that is controllable. This is a good choice to weld
very thin metals together. If you are working with aluminum or
stainless steel this is a good choice.

___________________________________________________________________
___________________________________________________________________

Here is a link to a Web Page that covers this first email:
http://www.WelderWorld.com

Have a good one,
Ivan Irons
WelderWorld.com

P.S.
There is more…If you sign up as a member of Welder World Community, you
will get special access to 2 Free eBooks on the site. The eBooks
are about Welding Basics.  Here is the best part, becoming a member is Free!

Wait…The Welding Basics eBooks are Free!
Yes!

What do I get out of it you ask?  A bunch of like-minded Welders and Metal Working Friends
around the world!

Sign Up Now to get all these Welding Benefits!
http://www.welderworld.com/index.php?option=com_comprofiler&task=registers