Welder World Blog

Archive for February, 2011

Welding Machine is equipment, which is used to weld or joint two metals or alloys together using another metal component as filler. Usually structure-less metals and alloys are joint using welding machines to give them desired shape and make them sturdier than they would be if it were a single piece.

These machines are available in different sizes as per their utility. A large size machine would be used in a factory and a handy machine is available for domestic purpose. Types of machines that are available in the market vary from Arc welding machine, Fusion-welding machine, Plasma Cutting machine, Resistance welding machine, Solid State Welding machine and less known types are Induction and Thyristorised welding machines.

Among all the types, Arc type machines are the most efficient and effective. According to the type of material used to weld, they are broadly classified into three categories.

Common most is the Manual Metal Arc mechanism. The tool looks like a stick, which performs the function of a main electrode, and it is covered by a flux that prevents it from oxidization. With the help of electricity, the electrode melts itself continuously for welding the metal. This equipment is mostly used for small tasks. This kind of machine is usually used in construction industry, maintenance and repair of small metals, cutting and making holes in steel products and rebuilding fixtures.

Second form is a Metal Inert Gas mechanism which is a large bobbin like formation. It is a single piece of equipment that includes a mix of argon or helium gas or both used along with the heated electrode to camouflage the metal from rusting. This makes the task easy and quicker. Metal Inert Gas equipments are mainly used in shipbuilding, power plants, aerospace equipments, automobile industry, bridge constructions and refineries.

The third kind is Tungsten Inert Gas, which has a single electrode, and the protective material is provided by another resource. The electrode does not thaw out as it has an additional tool to give it protection. This type of mechanisms is used in large factories where it is impossible to use other type of welding machines. Principally, Tungsten Inert Gas machines are used in power plants, construction industry, aerospace industry and manufacturing industry for more robust and specialized welding.

Apart from these, other type of welding machines that are available in the market are:

Carbon Arc, which is used for welding alloy steel and water jet cutting.
Orbital or Tube Arc is used in casting, shipbuilding, automotive industry etc.
Plasma Arc is used for welding of surgical instruments, food industry, dairy industry etc.
Stud Arc is mostly utilised in fabrication and machining.
Submerged Arc is chiefly used in industrial welding and pipe welding.

Any industry usually uses a combination of any of the above machines as per requirement. Welding machines are easy to use but is a complex piece of machinery and hence should be operated under expert guidance.

Welding is a not like other jobs and it is called as a skilled art and it needs lots of practice and patience. We all know that tungsten inert gas welding is used for complex and stylish process and the welding machine used for this purpose is called as tig welder and in this article, let us deal with various tips on tig welding and tig welders. Using tig welding machine is not so easy and pick up the electrode for the mission you start. Crush the electrode to a position and aim for a sharp tip so that it becomes more rounded as you weld. Put the electrode into an electrode holder that has the tip about 1/4-inch away from the cover and go for the settings on your tig welding machine. AC, DCEP and DCEN are the three important ones and prefer AC for aluminum.

Position the air on to five seconds and turn the max amps to 250. Also turn on the gas and different gases are used for different metals, for example, use pure argon for aluminum and use argon and carbon dioxide mix for steel. Brush your welding table or level piece of sheet metal with a wire brush so that it will be clean and flat. Welding Gears are essential during welding and the welding safety gear includes goggles, apron, hood and gloves. Make sure that you have all these welding gears so that you can weld safely and as said above, a clean place is essential so that you can work in a safe environment. Holding the electrode is considered while doing the tig welding. Grasp your welding electrode in your hand that is dominant and start your welding project. Ensure that every setting is proper and make sure that they are not changed or wrongly adjusted.

Choose tig welders count while doing tig welding because only a proper welding tool can improve the performance of welding process. Counterpart the metal type you want to weld and for case, if you require a welder that are proficient to weld hard metals like steel, cast iron or bronze, then only an alternating current (AC) welder can work well. AC welders operate using electricity that “alternates” direction back and forth. For soft materials, DC welder is strong enough to weld and it creates a stable arc for welding. Make your mind up on how thick of metal you are going to weld and based on the thickness, select high amperage or low amperage welder.

Duty cycles comparison is essential while buying welding machines and compare the duty cycles and it is a term that indicates how long the welder can operate. Select a tig welder that you’re your budget and in general it costs from Make certain the tig welder fits your budget. 0 to ,500, and the rates vary depends upon the power and company. While buying it, compare the features and warranties so that you can be able to get the best welding machines in an affordable price.

Stick welding is known as the process that makes use of a covered electrode called stick. Also, known as Shielded Metal Arc Welding or SMAW, stick welding is the most widely used method today than other welding methods. But, now the question is how do they work?

The equipments used:

Stick welder contains circuitry inside the machine, which enables to carry a specified amount of voltage, therefore creating an arc. And, this is the reason why these welders are sometimes referred to as ARC welders. Totally relying on the application as well as on the machine, the current can be either alternating or direct current. The circuit board, which is present inside the welder enables it to ground the negative to the positive by creating heat without burning the electronics.

Shielded Metal Arc Welding (SMAW)

The welding procedure with the help of stick is called shielded metal arc welding or SMAW. The welding stick is a metal, which is coated with a flux material that burns off when the arc is struck, thereby creating a gas that protects the weld created. This type of welding is the most preferred method for the purpose of large metal structures like building framework, etc., because of its versatility and penetration ability. Although, today, other welding process like Flux-cored welding, or wire feed, is gaining more popularity, but stick welding still dominates the field.

The Weld:-

Factually, there are two types of leads that occurs in a stick welder. One lead is the negative clamp, and the other is the positive lead. In positive lead, the consumable metal stick is placed, while the negative lead is clamped on to the metal that is to be welded. During the process, when positive lead containing the stick comes in contact with the metal, an arc is created that further burns into the metal surface. Throughout the arc burning process, the stick is also burned, which thereby creates the weld. And, this is why welding is considered different than that of soldering process.

Safety Measures

While getting indulged in the process of welding, it is imperative to consider certain safety precautions to get rid of the risky environment. Always make sure to wear a welding hood when striking an arc. It is known that harmful UV rays are produced during the welding that can lead to burn in the eyes, so it is advisable to wear suitable goggles during welding. Also, wear leather welding gloves and a long-sleeved leather jacket, as well as heavy footwear and jeans. Remember, to remove all the inflammable materials from the work area before welding. So, consider the safety measures in order to get clean and successful welding.

Related Stick Welder Articles

TIG welding is considered as the most  flexible process of welding as it can easily be merged with all the conventional metals such as Carbon and low alloy steels, stainless steel, nickel alloys, aluminum, magnesium, titanium, cobalt, and copper alloys. TIG welders also known as the Tungsten Inert Gas Welders makes use of an arc which is been created from the non-consumable tungsten. The heat is generated through electric current for the welding process.

Moreover, this kind of welding has several benefits like the high amperage in it allows the welding of metals with great thickness; also it include the concerns related to the purity of metal and its cleaning. In addition, welding is known as a skilled technique that requires lot of practice, patience and safety gear. TIG welder is one specific kind of welder. TIG welder is mainly used for complex and stylistic welding. Described below is certain tips that you need to consider while using TIG welders.

Instructions

1. Make sure to pick the better electrode in order to use for the project you are starting with; also you can make use of variety of alloys such as the 6061 Aluminum alloy electrode.
2. You need to grate the electrode to a certain point. Try to create a tip and sharpen it to make it more rounded as you weld.
3. Place the electrode into an electrode holder with the tip about 1/4-inch away from the case. You can choose the settings on your TIG welder. In fact, the three major ones are AC, DCEP and DCEN. You can choose AC for aluminum.
4. Remember to set the air on for five seconds with the max amps to 250. Also, turn on the gas. While using aluminum, you can use pure argon. For steel, an argon and carbon dioxide mix.
5. Scrub your welding table or the flat piece of sheet metal with a wire brush in order to make it clean and flat.
6. You can gear up the full welding safety gear including glasses, apron, helmets and gloves.
7. Always, hold the electrode in your dominant hand and you can start up your welding project.
8. You need to check your settings frequently to make sure they have not changed and you can adjust them as required.

More Used Tig Welders For Sale Articles

The welding principle is quite simple. The welding machine, whatever its type and size – applies heat to the two metal pieces that are to be joined. This heat causes the two metal pieces to melt slightly to form a liquid. A filler material made from tungsten or a metal alloy is often used as a filler material between the two pieces. When the heat from the welding machine is withdrawn, the liquefied metal and filler quickly solidify to join the two units.

Flash butt welding is an advanced and innovative technique for joining mild steel, alloy steel and other dissimilar metals in various tubular or solid forms. Flash butt welding may be described as a technique for joining segments of metal rail or pipe in which segments aligned end to end are electronically charged, producing an electric arc that melts and welds the ends of the segments resulting in a remarkably firm and smooth joint.

When two wires, which are charged with electricity, are made to contact with each other, they crackle with sparks. The flash-butt welding is a welding method which harnesses this heat of which sparks generate, to melt and to weld metals.

The striking feature of flash butt welding is the resultant weld quality is similar to the parent metal. No additional tools like rods or gas is required and that makes flash butt welding highly economical. Other important features of flash butt welding include – no elaborate preparation, high accuracy of welded joints and high consistency of weld parameters.

Generally speaking, there are three basic types of butt-welding and you adopt one or the other depending on the thickness of the metals to be joined. For thin metal sheets or plastic, you can choose a square weld joint. In such cases, the edges of the metals form 90-degree angles to one another and can be butted together with ease. This is the most economical and common type of butt-welding joint.

When you weld thicker materials, the edges must be beveled to form either a single or double V-groove. A single V-groove is meant for metal pieces of moderate thickness including almost all varieties of pipes. Filler is usually placed on the wider part of the V-groove to provide firmness to the weld. As regards a double V-groove, both the top and bottom of each object is beveled. Filler is placed on both sides and heated in alternating patterns to achieve the most secure weld possible. This double V-shape is more meant for extra thick or large pieces.

Butt-welding is widely used in a wide variety of manufacturing industries, at construction sites and in specialty welding shops.  Applications include wheels, aerospace, structural members, rings, rods, stationary rail application, anodes, bands etc.

There are available in the market Flash Butt Welding machines for many applications from the smallest to the largest. There are also welders specially designed for heavy duty applications where repeatability in performance is the key. The manufacturers also supply necessary tooling and clamping devices for adapting these machines for the production of railway shackles, automotive parts, starter ring-gears, wheel rims, chain links and assembly of parts by links etc.

Related Butt Weld Articles

MIG welding, as most of us are aware, is a semi-automatic arc welding process in which a continuous, consumable wire electrode and a shielding gas are fed through a welding gun. At the end of the gun, there is a contact tip which passes electricity to the wire. Both the wire and shielding gas are activated to create the weld when the operator depresses the trigger of the gun.

Pros of MIG welding

MIG welding is quite popular as it is easy to learn and calls for no special skills. Even a first-time operator will be able to achieve a good weld with minimum practice. People favor MIG welding as it is a much faster than Stick welding and saves time. Thus operating cost of MIG welding is lower than Stick welding because of this saving of time. MIG adjusts to limited electrode length and this allows for longer welds with fewer interruptions.

Besides, there is also no waste of filler metals and generally speaking, thinner materials can be welded far more easily with MIG than Stick welding. One more reason people favor MIG welding is because MIG welding is a tidy process and does not require chipping slag as in Stick welding. MIG certainly makes for very convenient weld tacking and fitting of parts and there is very scant stub loss due to the continuous spool of filler metal.

MIG welding is versatile and capable for a variety of applications, including – trailer hitches, auto body repair and restoration, farm/ranch equipment, household projects, repairing wheel barrows, bicycles, etc. This type of welding demands less time when compared to other types of welding processes.

Cons of MIG welding
The initial cost of MIG set up is high in view of the regulators and shielding gas – though some MIG welding may be done with self-shielding flux core and without gas or a regulator.

It is indeed a fact that all types of material can be welded with a MIG machine. But, in the MIG process different materials require different wire and gases. For instance mild steel can be welded with either self-shielded wire or with CO2 or a CO2 mixed gas but aluminum material requires the use of Argon gas.

It is inadvisable to weld through dirty materials with MIG machines. It is said one should always weld on the cleanest possible material, so for best results scrape off paint, rust or other debris where the weld is being made.

There is no denying that MIG welding equipment is more complex, expensive and less portable and the welding gun is difficult to maneuver. Filler metal can become tangled within the wire feeder making the operator feel annoyed and also adding to downtime. The operator has to patiently keep leads and liners in straight position to allow for proper feeding of filler metal.

Summing up
When electrically charged wire is feeded into the welding arc then it is MIG welding. MIG is commonly preferred because the welding leads are very easy to perform. As a matter of fact, it is said that even robots can be utilized to get the mechanical job done. MIG welder is capable of working with almost all kids of metals, though aluminum and mild steel are the most popular ones.

Welding is the process of joining materials, usually metals by melting the pieces and adding a filler material to form a pool of molten material, which later cools down to become a strong joint. Spot welding is a process of joining metal surfaces with the help of heat obtained from resistance produced by the flow of electricity.

An experienced welder would require specialised welding equipment like Spot Welders for a spot welding job. A spot welder is a machine that has copper alloy electrodes that can force a heavy electrical current at a particular spot where welding has to be done. This produces a lot of energy in the weld spot in a very short span of time. This process requires electrodes to produce optimum heat on the weld spot without heating the rest of the surface of the metal pieces or sheets being joined. However, the thickness of such metal pieces or sheets must be within the prescribed range for spot welding to be successful. The most important aspect of spot welding is to have control over the energy being delivered on the weld spot to produce fine quality welding.

For deciding upon the amount of energy required for spot welding, one has to take into account the properties of the sheet material or metal pieces that are being joined along with their thickness. One also has to choose the right electrodes to be used in the process of spot welding for best results.

Spot welding is a specialized job that is best handled by workers having hands-on experience in spot welding as is an extremely difficult task to define all welding parameters correctly because of the sheer complexity which compounds because of the numbers of metals that might need spot welding and the various types of electrodes that are available for spot welding. One must remember that even the smallest of change in one parameter can affect the other parameters of spot welding and the results may not be what were expected.

The hold time is the most crucial parameter for a successful spot welding job. Hold time refers to the time lag after the welding when the electrodes still adhere to the metal sheet to chill down the spot where the weld has been made. If hold time is too long, there is always a risk of the weld becoming brittle.  You may require a longer hold time to spot weld galvanized carbon sheets.

A video describing the Resistance Spot Welding Process

There are numerous fat burning foods out there that help to boost your metabolism and in turn, help you lose more body fat. With a precise diet and exercise plan, these foods can give you an extra boost in your daily caloric expenditure. Over time, it all adds up with more weight loss without putting in any extra effort. So without further ado, here are my top 3 fat burning foods.

Coffee – Coffee is a potent fat burning food. This is mostly because of the caffeine present in coffee. With decaf you won’t get the same effects. Caffeine has been shown to increase your nervous system output, increase your blood pressure, heart rate, and metabolism. The effects can be more potent if ingested 30 minutes before you workout as its shown to be a performance enhancer.

Green Tea – Green tea is also a very important fat burning food. This is why you see a lot of weight loss products on shelves and on television promoting the effects of green tea. This is because of a compound found in green tea called ECGC. It is the main component in fat burning when ingested. Green tea is also very healthy and has been found to be high in antioxidants.

Salmon – Salmon is such a great source of protein and healthy fat that everyone should be getting at least 3 servings a week or 30 grams of fish oil per week. Omega 3 fatty acids, the prominent fat found within fish such as salmon has been found to lower leptin levels. Leptin is a hormone that is correlated with your metabolism. Lower leptin levels equals a higher caloric burn.

These are just some of the foods that have been shown to burn belly fat.

You can find more in your free Blowtorch Belly Fat Manual that I give away on my blog.

Who says you can’t use a blowtorch to speed things along in the kitchen?
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Welding Tips Show #10 | MIG Welders vs. TIG Welders. In this episode we talk about the pro and cons of MIG welding machines and TIG welding machines. If you’re a beginner welder and trying to decide which is best for you, you don’t want to miss this episode.

Welding Tips Show #10 | MIG Welders vs. TIG Welders. In this episode we talk about the pro and cons of MIG welding machines and TIG welding machines. If you’re a beginner welder and trying to decide which is best for you, you don’t want to miss this episode.

There are numerous risks associated with the insurance of construction jobs; this article will analyze those risks and discuss the various policies available to protect against them.

There are a number of factors that an insurance underwriter must take in to consideration when evaluating the risk a certain project contains, starting with a detailed explanation of the project itself and the scope of work planned. Other details such as the type of construction that will be done as well as site information including topographical and geological conditions must also be considered. The constructions drawings are examined, along with the estimated project completion date; the contractor’s knowledge in the particular technique of construction used is also considered.

Material Damage refers to any destruction that accidentally occurs as a result of the contractor, which is an expected part of the construction process. Even these common factors and exposures can be protected by an insurance policy. Contractors Plant and Machinery All Risks, Erection All Risk, Contractors All Risk, and Civil Engineering Completed Risks are some of the kinds of policies that cover the Material Damage that contractors face.

There is also the possibility of having to pay compensation for claims by third parties for personal injury or property damage resulting from the works. Liability Insurance covers these risks, which includes Employer’s Liability and Worker’s Compensation, along with General Third Party Liability and Public Liability protection.

It is possible that a contractor may default under the terms of the contract and reimbursements. Other coverage provided by the Contractors All Risk Policy, the Erection All Risk, and Civil Engineering Completed Risks will give coverage for construction projects to protect against any losses which can be caused by a myriad of factors. These can compensate for damage that results from theft, burglary, civil unrest and strikes, riots, flooding, earthquakes, hurricanes and fires.

There is also a policy that will compensate the employer if the construction is not finished as expected; this policy, entitled Advance Loss of Profits, will provide for any anticipated profit lost as a result of this delay. When the amount to be insured is being decided the Contractors All Risks, or Erection All Risks, policies will be involved. The reason being is that these policies protect the construction project against compensation costs due to damage caused by contractor negligence.

You will find that there are few construction projects in which there is only one company working, because more times than not companies will come together in order to finish a project. If this is the case you may have some question about who is responsible for injuries and damages incurred by third party persons. These third parties may include other sub-contractors, project owners and staff, and neighbors, all simultaneously involved.

The responsible party or parties for any loss or injury will be identified. Additionally, the claimants will try to present proof that it was negligent conditions at the build site which are responsible for their loss. This concept is known as “public liability” or “general third party” in legal circles.

If the contractor has gotten a Public Liability policy, he will not have to pay out of pocket any money that he becomes legally obligated to pay. This payout will be the compensation paid to the third party for any damages done to their property or any personal bodily injury incurred. Two factors influence whether compensation will be made, and they are instances where a nuisance resulted from the works, or injury or damage was caused through the contractor’s negligence.

The employer’s liability is akin to the public liability policy. This policy, however, will enable a contractor to provide his employees with compensation for any damage or bodily injuries to their properties. This compensation is dependent upon whether the cause was due to the employer’s negligence or was due to a nuisance which resulted from the works.

Because of the factories act and other related safety acts that were designed for the protection of employees, contractors have statutory responsibility to guarantee employee safety. These regulations incorporate the fact that an employer needs to provide a working environment which is not dangerous, including nontoxic materials, and the correct tools and equipment to complete a project. The employer is also responsible for choosing workers who are able to complete these jobs, and supervise their workers properly while at the build site.