Welder World Blog

Archive for March, 2011

This is what we are going to discuss. It is a known fact that Welding is a sculptural process that joins two metals by the process of welding and Weldor is a man who does the welding process. Compared to other industrial jobs, welding is fairly dangerous and the occupational and health hazards of welding can be avoided with proper equipment, safe materials, and a few common sense measures. Welding tools and welding equipment are essential in welding services and the manufacturing industries fail to meet the demands, if there are no proper welding tools and welding products.

The process of welding was there from 310 AD itself and the first welding process introduced was forge welding, and later on many welding processes were introduced to weld different types of metals. From the decade, welding has developed a lot and new welding technologies with advanced welding equipment and systems have been introduced. Historical monuments, construction of building, bridges, ship building, automobile, aerospace, power plants, refineries and all manufacturing activities need the process of welding. 20th century started good for the welding process because it saw many new welding processes and technologies.

Stick welding, tig welding and mig welding are the welding process that is used frequently in welding industries. All these welding equipment needs the appropriate welder machines and the welder machine is an equipment that is used to make weld. The arc welding process is categorized into two types depends upon the usage of its consumables. The mig welding comes under the consumable electrode method whereas tig welding comes under the non consumable electrode method. The tig welding use the tungsten electrode as its consumables and by using this process, steel, aluminum, magnesium and copper alloys are welded.

Stick welding method is primarily used to weld iron and steels. Mig welding process is originally developed to weld aluminum, but later on it is used to weld steels. Different types of welder machines are available such as mig welder, tig welder, on board welder, reconditioned welder, aluminum welder, steel welder and metal welder can be used for the process of welding. Consumables available for welding are tig consumables, mig consumables, plasma cutter consumables, tungsten consumables and welding accessories are the tools that are attached to welding machines, and it is used for the better performance of welding.

Modernization is what most of the welding products is, on roll capacity of wires, extended wires, portability and compatibility is its features. These welders machine can be typically used in all industrial applications from light fabrication to aerospace. Welding accessories such as foot pedal, air regulator, ground clamp and argon regulator are essential to support the welder machines. For the weldor’s safety, each and every industries should be equipped with welding gears such as welding helmets, welding clothes welding goggles and welding gloves for the safety of the weldor.

The manufacturing industries should be aware of all the welding tools and welding equipment for the better development of their industries.

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The three best welders that have been ruling the welding industry are arc welder, plasma cutter and tig welder. Even though different types of welding machine exist, these three machines are called as the best welding machines. Why it is called so? It is called so because it has all the features and qualities that best suits the welding industries. Arc welding has been called as one of the oldest type of welding process and tig welding comes under the category of mid type welding process and plasma cutter have now joined in the list of modern welding machines. So in this article, let us see why these three welding machines are called as the best welding machines in brief. Let us first start with the oldest type of welding process called as arc welding and the arc welding process.

Arc welder is a device that joins the more pieces of steel or metals together and it has the capability to generate enough heat so that it can melt the pieces of metal or steel in a quick way. Arc welding is in practice from 1802, but the welding machines that were invented in those days were not portable and it was very heavy to carry and leave outside more polluted gases. Whereas now the arc welders that is in existence has excellent features and weld the metals in an easy way. It is available in different types in market in affordable prices. Power arc 160 and power arc 200 are the two welding machines that are available in market now. Both these types are of Infineon igbt inverter type and it is typically used in different applications and also has good hot start.

The next welder that we are going to discuss is plasma cutter. It is called as the scientific and modern welding features and preferred more by different industries due to its excellent features and reliability. It accurately cuts the metal with ease and it uses high voltage electrical arc and plasma gas so that it welds the metal quickly and easily. In market you can find different types of plasma cutter welding machines such as super cut40, 50, 50p, power plasma 50, 60, 70, 60E, 80 and 100. Each type has over current warning facility and cuts the metal of different thickness. It is widely used in different industries and also cuts as faster than any other welding machines. It has good duty cycle and also accuracy is its advantage.

Tig welder is a non consumable welding process and it has been developed in a fast way with good features. In market, the following tig welders are available and they are power I-tig 200, powertig 185 micro, powertig 200DX, powertig225LX, powertig 250 EX and powertig 315DX. As like other machines, it also has best features. So when you buy these three welding machines, buy with care so that you can buy the best one and efficient one.

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Many people go to the store for a welding machine and they know exactly what to buy. When you are going to buy a plasma cutter there are more issues to take into consideration because of the way it is made.

When you are looking for a plasma cutter the first thing to consider is what you will be cutting most of the time. Plasma cutters are generally rated by how thick the material is that you will be cutting so it is important to make sure that you do not have a machine that will undercut the metal you are working with most of the time.

As you look at plasma cutters study each make and model to see what they do and how they do it. You will choose one that will fit your needs for what you want to do. One way to do research on this is to go to online forums that discuss this topic. People will talk about what they bought, what it does, why it works for them and more.

What Brand To Buy

This is not something that can be answered for you because you will have to decide based on what you need. There are four major brands: Miller, Hobart, Firepower and Hypertherm. Each of these is a good brand but they all have different prices for lots of different plasma cutters. You will need to shop around and comparison shop before you buy.

The Power of the Output

Each plasma cutter will have a certain amount of power it puts out depending on the thickness and the type of material that you are going to cut. The thickness will also tell you the right sized nozzle opening that you will need and it will determine the type of gas, the amount and the air that you will need to use it.

The way to figure this out is to think about the type of metal you will be working with most often and then check the cutting capacity that the machine has that you want to buy. Also, check the cutting speed because some plasma cutters are faster than others which cuts down on the time it takes you to produce your work.

Finally check the amperage that you will need. Someplasma cutters are able to use multiple currents and this may be important to your needs.

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Welding is in fact a complicated and vast subject to deal with and in this article you can learn about how you can turn you welding hobby more useful and good going. This article will be covering is a number of extremely essential necessities and a few of the fundamental beginner choices that anyone who starts off with welding can choose according to their requirements and comfort level. As we have a lot of welding techniques, it is wise to select the easiest and best techniques according to the person who learns it and according to the purpose.

People like to learn welding for many reasons and some want to learn it as it is a sensible and useful relaxation. People who learn welding for hobby make use of them for different practical daily activities like building mopeds, yard art, handy shop tools, repairing equipments just about their home. Welding is in fact a very much useful and rewarding hobby to be learnt and practiced as we get to handle a lot of modern welding equipment so easily unlike earlier times.

There are mainly four fundamental procedures of welding, which people commonly use these days. Oxyacetylene welders are the technicians who use a flame to melt the metal that is needed to be worked on and develop the weld pool. Then a welding rod will be inserted into the weld pool which is in the molten state to fill the weld.

In the stick welding process a welder will make use of an electrical arc to produce heat and what happens next is a flux is formed due to the heat and this is helpful in fusing the two metal pieces. This method by which an electrical arc is being used is known as Shielded Metal Arc Welding or widely known as SMAW. In stick welding, an electrode is the one which is used as the filler.

The process of MIG welding is also known to be as the gas metal arc welding process or GMAW. The Gas Metal Arc welding is a process in which an electrical arc to produce the welding heat that is required to produce the flux. This method has an extra thing called the shielding gas which is made to protect the molten weld pool. Then the material which is used as the filler is delivered through a wire feeder.

Then we have something called the TIG welding and this produces the electrical arc by means of a Tungsten electrode and also has a shielding gas.

Apart from these basic types of welding there are a lot more to know, learn and practice but all of them are for industrial uses and a hobby welder need not use those heavy machines. If you are turning out to be a hobby welder it is better for you to know that a welder machine is quite expensive and try making sure about the projects you are thinking about and get machines according to that- buying all the machines might not be a sensible decision. Oxyacetylene torches are the ones that are mainly adaptable and versatile of all welding methods and it is advisable to follow this method.

HDPE Pipes Repair Solution

High Density Polyethylene (HDPE) is a term that is used with pipes and linings. High density polyethylene pipes are more durable then A normal polyethylene pipe as it has low density. A number of people have started using HDPE pipes for its durability and long-lastingness in their home and offices. Modern pipe liner uses HDPE pipe repair and maintenance method with traditional resistance process as well. HDPE pipes have a thicker lining and last longer, and thus are getting popular everywhere.These pipes are light weight and can be installed easily at any place when needed.

HDPE pipe repair :

Even though they are durable but to protect HDPE pipes we must acquire knowledge on professional HDPE repair & installation as a pipe leak can happen anywhere, any time and without warning, and can threaten to shut down your entire operation, resulting in costly downtime and product ion loss.

(1) Instant Effective Pipe Repairs :

There’s no better solution for instant effective pipe repairs than Rapp-it Pipe Repair Bandages.Rapp-it is a roll of fibreglass bandage impregnated with water-activated polyurethane resin. Every pack of Rapp-it includes the bandage, a stick of epoxy putty and a pair of gloves. It’s simple to use with no mixing or measuring required, yet results in a strong, superior pipe repair. You simply immerse the bandage in water for 10 seconds, and then apply by wrapping around the damaged pipe area. A successful pipe repair can be achieved in only 30 minutes.

(2) Long Lasting OR Permanent Repair Method :

There are a number of methods to pipeline repair that include weld and non-weld, numerous non-exhaustive, external and internal replacement methods.

(1) Plastic extrusion is the most popular method Among all as it is the efficient and effective way to access pipelines without disturbing your premises. And,

(2) To prevent leakage you can use HDPE pipeline liners but these liners must be installed by Pipe Liner Specialists.

(3) The open-cut excavation method is also used for the pipeline repairing, however it is costly and requires loads of time.

(4) Another method of HDPE pipes repair is the trenchless pipe rehabilitation method. This procedure helps in to stop any kind of existing leakage and the further harm of the pipe lining system.

While selecting the method of repairing HDPE pipeline you must keep the safety issues in mind and make sure you go for Professional HDPE Repair & Installation for long lasting results. Ask for services of Pipe Liner Specialists for better results.

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Historical monuments, construction of building, bridges, ship building, automobile, aerospace, power plants, refineries and lots of manufacturing activities needs the process of welding and it is a part of it. Manufacturing activities need proper welding technology to meet the demands and welding system is the backbone of all manufacturing activities. It is a fabrication process that joins metals, materials and thermo plastics.  When you consider the history of welding, forge welding was the only processes introduced first and later on arc welding, oxy fuel welding and resistance welding were developed. 20th century started good for the welding process, it saw many new welding processes and welding technologies.

Mig welding, tig welding submerged arc welding and flux core welding were developed during 20th century and new welding equipment with latest welding technology were introduced later. The manufacturing industry came to know about the importance of welding services and requirement for welding supplies increased a lot. To cope up with the heavy requirement, welding industries started to use new welding tools, welding products, welding accessories and welding equipment supplies that are designed according to the latest welding technology. Welding techniques is classified into two methods based on the welding consumables such as consumable and non consumable electrode methods.

Shielded metal arc welding, gas metal arc welding, flux-cored arc welding and submerged arc welding are the welding techniques that come under the consumable electrode methods. Gas tungsten arc welding, plasma arc welding, atomic hydrogen welding, electro slag welding and stud arc welding comes under the category of non consumable electrode methods. Tig welding uses tungsten welding electrode and consumable techniques use welding electrode rod or stick for its process. Many industries use inverter welding machines and there are different welding machines for different welding techniques. Apart from the welding products such as mig, tig, stick and submerged arc welding products, the other products such as wire feeders, spot welders, multi process units and water coolers comes under the welding products.

Plasma cutter the new invention comes under the category of cutting products and apart from plasma cutting, plasma gouging is also done in the same welding machine. Different types of welder machines are available such as mig welder, tig welder, on board welder, reconditioned welder, aluminum welder, steel welder and metal welder are used for the process of welding. Welding fumes are dangerous, so the weldor should be protected with welding gears such as welding helmets, welding masks, welding gloves and with proper welding accessories. Welding guns and welding torches are important to weldor and the weldor should have proper control over it.

Consumables available for welding are tig consumables, mig consumables, plasma cutter consumables, tungsten consumables and welding accessories is an optional tool that are attached to welding machines and it is used for the better performance of welding. In 1881-1882 a Russian inventor Bernardos created the electric arc welding first and welding process was a tough and nobody was willing to learn welding, but today welding schools were started to learn welding and we can learn welding easily through virtual reality.

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If we take a look at modern industry we can see that it largely depends on the manipulation of heavy metal and alloys. Metals are being used to build the tools and transportation necessary for day-to-day businesses. Everyday huge equipments are made including cranes, cars, skyscrapers, robots, and suspension bridges using precisely formed metal components. This is because metals are extremely strong and durable and for anything that has to be big and sturdy, metal is the perfect choice.

Since the metal is so sturdy, it is really tough to cut and mend it desirably. Due to metal’s strength, it cannot be manipulated easily to form into specialized pieces. Here the plasma cutters are of great use for cutting the metals. The plasma cutter works by binding one of the most prevalent states of matter in the visible universe; plasma. The plasma cutting machines come in different shapes and sizes. There are monstrous metal cutting machines as well as portable plasma cutters.

The plasma cutter is basically a simple and relatively easy to use tool to cut steel and other electrically conductive metals. The working of plasma cutter is done using a high voltage electrical arc and compresses gas, which would normally be air. A concentrated arc of plasma is created at the cutter’s tip as an electrical arc generated by an internal electrode ionizes gas passing through a nozzle. A high circuit is developed as the arc comes in contact with the working surface thereby melting a section less than 1/16″ wide. The force of the plasma then completely blows out the molten area on the work piece. Thus a clear cut takes place without any slag. The speed at which plasma arc travels through the nozzle would be up to 20,000 feet per second and the temperature would reach as high as 30,000 degrees Fahrenheit.

Coming to talk about the power used by plasma cutters, it has been seen that light portable plasma cutters take in 110 volts with an output of around 12-35 amps. On board air compressors are often found in these machines in order to simplify their use. The large plasma cutters would have an output between 50 and 80 amps and they would be 220 volt systems. For cutting any conductive metal up to ½ inch thick, hand-held plasma cutting equipments would be available. However, for industrial purposes larger ones are used which can cut through 2 inches of metal.

There are many advantages in using plasma cutters in welding industry. One of the main advantages is that during plasma cutting the surface of the metal outside the cutting area remains relatively cool. This would help in preventing the warping and paint damage that happens with other flame cutters.  For precise curved line cutting, there are thin heat affected zone (HAZ) also allows the use of templates. Since the plasma does not rely on highly flammable gases, they have the capacity to cut up to five times faster than traditional torches. Sometimes the plasma cutters act as gougers and are capable of cutting metals accurately and quickly.

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There are plenty of items found around the house which are made of metal, like the stove and toaster; these are made by means of metalworking machines. The industries on metalworking have been playing a significant responsibility in the manufacture of Metal Working Machine we are using in our everyday existence. As proven by the International Trade Administration, the metalworking industries in the U.S.A. consist of 2 sub-sectors; the industrial tooling and the machine tooling sectors. The industrial tooling sectors include approximately 7,000 business groups that principally manufacture industrial molds, dies and tooling devices. The machine tooling sectors include around 550 companies which produce mainly machinery. Several of these companies make tailored parts and they are smaller. Equipments that are numerically controlled (NC) that include an electronic controller and also machine tools, run majority of metalworking machines. Currently, most NC machines are controlled numerically by computers, wherein the computers work as controllers. The controller leads the tool parts of the machine by means of the dissimilar positions detailed in the directions, like moving the borer to the particular metal pieces as well as drilling holes. The computer-run manufacturing schemes make use of the computer numerically controlled (CNC) machine tools frequently. Even though the machining is mechanical, the CNC machine tools should be run accurately to achieve the best possible benefit. In view of the fact that CNC machine tools are costly, trained operators cautiously watch the machine to avoid conditions that destroy the cutting tools or some other parts. The coverage of the responsibilities of the operators are based in the situation and equipment utilized. Definite CNC machine tools mechanically watch and do some adjustments to machine operations. If everything is set properly, the operator has to watch only as the machine runs. In other works, the operators must have more roles, like loading as well as unloading and changing programming or tools. The operators might also have to calculate the finishing part for purposes of inspection; however, this task is done by CNC machines. There are plenty of Metal Working Machine. Lathe is a machine wherein a piece of material is held and turned while being shaped by a tool. It also drills, cuts and sands. It rotates a block of material about a selected axis of revolution in order to finish the required work. The operator puts a material in 1 or 2 lathe centers, having one or equally moving in parallel plane. Lathes can make items such as metal candlestick receptacles and crankshafts. Fabrication means the manufacture of machines and some other equipment by means of cutting, shaping and assembling parts that are created from materials that are not processed. Steel production shops as well as machine shops overlap in their roles. Fabrication shops regularly focus in the preparation, assembly and welding, and machine shops are more focused on metalworking machining of parts.

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Panel Cutting Machines is a tool that is used to remove material from the workpiece by means of shear deformation. Cutting may be accomplished by single-point or multipoint tools. Single-point tools are used in turning, shaping, planning and similar operations, and remove material by means of one cutting edge. Milling and drilling tools are often multipoint tools. Grinding tools are also multipoint tools. Each grain of abrasive functions as a microscopic single-point cutting edge (although of high negative rake angle), and shears a tiny chip.

Cutting tools must be made of a material harder than the material which is to be cut, and the tool must be able to withstand the heat generated in the metal-cutting process. Also, the tool must have a specific geometry, with clearance angles designed so that the cutting edge can contact the workpiece without the rest of the tool dragging on the workpiece surface. The angle of the cutting face is also important, as is the flute width, number of flutes or teeth, and margin size. In order to have a long working life, all of the above must be optimized, plus the speeds and feeds at which the tool is run.

è Different types of the Cutting tools

Single-point cutting tools can be classified by their motion as linear or rotary, depending on whether they rotate while cutting. Linear cutting tools include tool bits (single-point cutting tools) and broaches. Rotary cutting tools include drill bits, countersinks and counterbores, taps and dies, milling cutters, and reamers. Other cutting tools, such as bandsaw blades and fly cutters, combine aspects of linear and rotary motion.

è Replaceable Cutting tools

Cutting tools are often designed with inserts or replaceable tips (tipped tools). In these, the cutting edge consists of a separate piece of material, either brazed, welded or clamped on to the tool body. Common materials for tips include tungsten carbide, polycrystalline diamond, and cubic boron nitride. Tools using inserts include milling cutters (endmills, fly cutters), tool bits, and saw blades.

è Materials used in the Cutting tools

Cutting tools are made using a variety of materials and the selection of a cutting tool material depends on a variety of factors.

To produce quality parts, a cutting tool must have three characteristics:

* Hardness — hardness and strength at high temperatures.

* Toughness — toughness, so that tools don’t chip or fracture.

* Wear resistance — having acceptable tool life before needing to be replaced.

Cutting tool materials can be divided into two main categories: stable and unstable.

Unstable materials (usually steels) are substances that start at a relatively low hardness point and are then heat treated to promote the growth of hard particles (usually carbides) inside the original matrix, which increases the overall hardness of the material at the expense of some its original toughness. Since heat is the mechanism to alter the structure of the substance and at the same time the cutting action produces a lot of heat, such substances is inherently unstable under machining conditions.

Stable materials (usually tungsten carbide) are substances that remain relatively stable under the heat produced by most machining conditions, as they don’t attain their hardness through heat. They wear down due to abrasion, but generally don’t change their properties much during use.

Most stable materials are hard enough to break before flexing, which makes them very fragile. To avoid chipping at the cutting edge, most tools made of such materials are finished with a slightly blunt edge, which results in higher cutting forces due to an increased shear area. Fragility combined with high cutting forces results in most stable materials being unsuitable for use in anything but large, heavy and stiff machinery.

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