Welder World Blog

Muna wa Wanjiru asked:


Welding is definitely a process more hazardous than others: there are all sorts of risk that workers are exposed to in case they fail to comply with safety measures. From this perspective welding hoods are an essential part of the equipment that protects the welder from the contamination with the toxic fumes that may result from the metal joining process; welding hoods are also great against the sparks that may hurt the eyes and face of the operator. These special tools suck up all gases and fumes that result from the welding process creating a safe working environment.

Welding hoods are considered one of the items of equipment that can be personalized, meaning that you may choose whichever design, color or model suits your taste and expectations. They come in a variety of models, sizes and prices as well, as we may say that the fancier the hood the more money you pay. Nevertheless beyond the display value, welding hoods provide all sorts of functional features the usually include auto-darkening according to a specific shade selection. Another facility worth mentioning here is the larger viewing angle you get from some of the welding hoods that combine UV and IR protection with easiness of operation.

There are some welding hoods that provide more control over the functions: thus you may select shade level, setting the one that suits the type of welding you are to perform or they enable the user to control lens sensitivity. Always try the hood on before buying it, the majority of the models available on the market are very light and comfortable to use for extended periods of time. In case you want to make sure that the welding hoods you want to purchase respect some quality standards, look for approved models that have special inscriptions to attest to their certification.

It is also important to keep in mind that the selection of the welding hoods also depends on the compatibility level with some other types of head gear. There are all sorts of configurations that match a model, but the weight, the material and the resistance to heat remain common features for all welding hoods regardless of the manufacturing company. Some companies use not just engineers and scientists at the creation of welding hood models, but welders too, since they are the first authorized to pass an opinion on a product or suggest a change in the quality of a product.

Welding Forum

Muna wa Wanjiru asked:


Like in all domains that require precision of execution, welding makes use of conventional standard signs that help to the better execution of a weld according to blueprints. The welding symbols systematized by the American Welding Society indicate the exact place where welds need to be made, the kind of joint necessary for it and the amount of filler to be used in the joint. Learning how to work with welding symbols is part of the training programs welders have to attend before receiving any certifications. What do welding symbols actually consist of? The main basic elements are the arrow, the reference line and the tail.

All welding symbols are built starting from the reference line, this is the very foundation of the sign as such on which you add other data necessary for the process. The connection between the reference line and the joint area is made by the arrow, but the direction of the arrow has no influence on the meaning of the reference line. Last but not least, the tail is not a compulsive element of all welding symbols, some have it, others don’t. It is generally used in case you want to add some information or supplementary specification to the process.

There are all sorts of peculiarities connected to the use of welding symbols. For instance, if any signs are included in the lower part of the reference line, you’ll have to make the weld on the side of the joint indicated by the tip of the arrow. In case the welding symbols are present on the upper side of the reference line, then the weld needs to be made on the side opposite to the direction pointed by the tip of the arrow. Both sides of the joint must be welded when you have signs included on both sides of the reference line. Deciphering such instructions from blueprints is essential for the proper working of the welding process.

Two kinds of welding symbols may appear on the reference line and they are essential when it comes to understanding how to make a specific weld. The most important sign here is a circle that means “welding all around”, thus, you will have to make the weld all around the joint in the direction indicated by the tip of the arrow. Sometimes it is not possible to weld around one single surface, and in such cases, the presence of the circle would be incorrect. Under such circumstances there should be other specificities related to the process.

Mig Welder

Muna wa Wanjiru asked:


The modern use of laser welding is rooted in the scientific discovery of the first laser in the 1960s, when the effects of an amplified light beam forced by radiation emission were put into practice. The working principle behind laser welding actually lies in the emission generated at the meeting point between light and metal, with the latter emitting force radiation. Presently, laser welding is expanding in various domains of activity since it brings enormous advantages with it such as a very deep weld penetration and minimal levels of heat inputs which cannot be achieved with traditional welding technologies.

The energy transfer is the one that makes the difference between classical welding and laser welding in various domains of activity. We can talk about two elements that characterize the efficiency of laser welding; first of all the heat ratio required by a specific workpiece and then the melting power in the fusion area. Furthermore, laser welding does not depend on AC or DC outputs and it is not limited by the conductive property of a specific material. The contact and fusion are possible with almost any material without even creating x-rays or requiring the formation of a vacuum.

The working principle in laser welding is the energy of light, hence the results are almost impeccable with a welded joint that has highly superior resistant properties. The penetration of a metal piece is directly influenced by its physical properties like conductivity, thickness or density; when a concentrated beam of energy is applied to a workpiece, the melting is immediate before heat may affect the operational area as such. The force of the energy beam in a focal point is given by the careful choice of special lenses. Correct mirror and lens applications in laser welding may guarantee the concentration of the light beam on spots smaller that 0.005.

The main industries to profit from the use of laser welding are aerospace building, military and defense, medical research, instrumentation, electronics and so on. Laser welding actually improved the execution of many delicate works that were almost impossible to achieve before, and here we refer to the creation of very deep or narrow welds and the absence of any distortions in the process. Small or very thin items could not be joint very well before the development of laser welding, not to mention that the resistance of the welds is incredible as compared to those resulted from classical welding procedures.

Welding Lessons

Muna wa Wanjiru asked:


Welding helmets are one of the most important items of protection equipment anyone in the business would need; welding exposes the workers to high intensity light, ultraviolets and infrareds that can cause irrecoverable retinal lesions. Welding helmets come in a variety of seizes and forms, but the most important thing is that they be both secure and comfortable. The best tools to use are the lightweight ones since, too heavy a helmet can tire the neck and the back, particularly since welding implies work in very awkward positions. Lightness is not the only feature of this piece of equipment, welding helmets also require durability.

Considered the best welding helmets available, the items with auto-darkening properties change their color within a fraction of a millisecond, as the electric arc is struck. The detection of the flash is so rapid that you don’t even notice the moment when the lens has gone dark; furthermore auto-darkening welding helmets offer protection even when the filter is not activated, this prevents the UV and IR from harming your eyes even in the absence of high intensity light. Regular welding helmets are not more expensive than $40, but the more sophisticated the technology, the higher the prices.

What does improper eye protection lead to? First of all we should say that developing certain work-related health affection is not uncommon at all, and it usually happens within years. The sight-hand coordination is not the same and cataract is often the consequence of faulty welding protection equipment. When choosing welding helmets it is important to be aware of the relationship between light intensity and the color shade of the protection item. The filter shade is the one that regulates the amount of light that reaches the eyes: too dark a filter may prevent the welder from getting work details, whereas too light a shade increases the risk of eye damage.

The filters of the welding helmets are numbered to indicate darkness degree; welders can make the right choice with the help of the standard selector charts that allow matching the filter shade with the type of application you need. At work completion, welding helmets must be cleaned of dust and dirt; there are special solutions designed to preserve the coatings intact. Afterwards, the equipment should be deposited in an area that is not exposed to direct sunlight, dust and moisture since such elements may diminish effectiveness.

Welding Forum

Muna wa Wanjiru asked:


The complex jewelry manufacturing process was already familiar with the use of gas welding even in mid nineteenth century, but only a combination of oxygen and hydrogen was used in the process since, together, they produced a very intense and hot flame. It was the discovery of acetylene at the end of the same century that made gas welding what it is today. Acetylene is a gas that results from the chemical combination of water and calcium carbide; in gas welding, this compound may provide flames with a temperature of up to 4000 degrees Fahrenheit. Presently, it is pretty common to use a combination of acetylene and oxygen in gas welding so as to achieve even higher temperatures of 6000 deg. F.

The advantages of gas welding include lower costs, mobility of equipment transportation and versatility, as compared to the use of electric set ups. Furthermore, there is no difference in terms of efficiency since any metal can be welded, cut or heated using a gas welding device on oxygen and acetylene. The materials are stored within cylinders under pressure, and they require extra tests and checks in order to ensure good functionality. If you choose gas welding, keep in mind the fact that the cylinders need to be kept in a vertical position, and that the valve caps must be in place when the cylinders are not in use.

The cylinders are connected between them and to the torch with all sorts of hoses, available in various sizes; one important mention here is that all hoses used in gas welding need to be marked with the type of service level they are meant for: heavy, standard or light. When purchasing the equipment, make sure that you know all the details for the rubber welding hoses. The gas mixture required in the process is achieved with the help of a torch mixer; yet, special care is required here since improper operation may lead to accidents. Gas welding exposes the user to the danger of combustion in the hoses and regulators; therefore, regular valve tests are required in order to prevent flashbacks.

Some gas welding equipments are especially designed to stop flashbacks; this is achieved with the help of a flashback arrestor. This device is similar to a check valve, but it also includes a trap that cuts of the gas flow in case a flashback occurs; consequently, arrestors are a must-have kind of equipment that prove essential for those who use gas welding. Cheap and easy to put into practice, they bring safety and comfort by decreasing the risks of material damage and operators’ injury.

Welding World

Muna wa Wanjiru asked:


In the many industry sectors where welding is required, companies have to tackle with various equipment requirements on a permanent basis: even if it all starts with the purchase or the renal of the welding equipment, continuous maintenance is part of the equation. All welding equipment is considered a good capital investment, due to its durability, functionality and applicability in various fields. The costs seem hire in the first place, but the money is afterwards recuperated in production. Additional to the new welding equipment, there are used and reconditioned items that may also be purchased for lower prices and with a good extent of functionality.

There are some pieces of welding equipment that could hardly grow obsolete, despite the scientific advances as such. For instance engine drives are relatively stable in terms of possible changes, since the main focus in the business is on the process and its optimization; these are classical and yet modern items of welding equipment that remain the buyer’s guarantee for a solid technological outcome. They provide simplicity, high quality and efficiency to the manufacturing as such. This would explain the fact that even second-hand drive engines are almost as reliable as new ones, since they preserve their value very well.

For new welding equipment trends, any investor has the opportunity of trying products and checking their quality before making any acquisition. This is possible thanks to the rental companies or the rent-and-own programs that suit both sellers and welding equipment manufacturers. Presently there are all sorts of complex products in the field that allow various automated applications at the same time. Modular systems for instance take a lot of pressure from the team operating the device; there are precise stops and starts incorporated in the motor as well as special devices to control large weight workpieces used on the machine.

Anyone interested in welding equipment may ask for quotes and product properties online; most distributors or manufacturers in the business provide a wide range of facilities in order to match the very demanding rules of a market with fierce competition. The analysis of the costs versus profits is a definite obligation any investor has in order to make sure that the purchase is worth making. Technical data are essential so as to know the exact features of the welding equipment item you want to get. There are even special teams that may even assist you with technical advice in order to make a good choice.

Welder News

Muna wa Wanjiru asked:


Welding depends on the electrodes for the creation of the electric arc, if these important items of equipment are not quality, then the whole process could suffer. Welding electrodes consists of metal wires covered in chemical coatings in order to prevent metal deterioration; this very structure makes the arc more stable or creates a better weld. There are several factors that determine the type of welding electrodes used: first of all the nature of the metal meant for the welding is crucial, then there are the machine and the work conditions as well. For instance, you cannot use the same welding electrodes for steel as for aluminum or brass.

Depending on their structure welding electrodes can be classified in consumable and non-consumable, the former are twice involved in the welding process, whether the latter contribute to it without suffering any changes. Some welding techniques require that the flux coating of the electrode be burned during the procedure: it may create smoke that shields the weld being made from the air around, or it can melt and mix with the metal for a better elimination of the impurities. According to a standard measurement, welding electrodes can be identified due to a numbering system that ranges from 1/16 to 5/16” in diameter; the best way to find the correct welding electrodes is to know which match the process you need them for.

One key-element for the safe preservation of the welding electrode properties is that it be kept dry, since humidity lowers the quality of the coating, which may finally result in a poor weld. This is why it is not uncommon to use special ovens to heat welding electrodes and eliminate all traces of humidity; this is the regular procedure when the electrodes have been exposed to a wet environment for more than several hours. You may also choose to deposit them in moisture proof containers in order to avoid future damage.

The metal-arc welding electrodes can also be classified according to the type of coating; thus we’re talking about heavy and light coated electrodes and bare electrodes. The choice of the best type depends on several peculiarities, corrosion resistance is first on the list, followed by material ductility, the position of the weld and the strength necessary for the welding process. Choosing an inadequate type of welding electrodes may severely affect the quality of work.

Welder World

Muna wa Wanjiru asked:


Getting a welder’s certification is not possible without attending some special training programs that are usually organized by welding schools and special institutions that are authorized for the matter. The duration of the classes and the welding skills you specialize in are the student’s choice, being closely connect to the costs as well. At the end of any training, tests must be passed so as to determine the level of knowledge accumulated necessary for the issuing of the certification. There are all sorts of schemes and projects that are provided by welding schools online so as to attract as many candidates as possible.

With a minimum duration of at least a few weeks, training in welding schools has also been included in educational curricula, being combined with on-the-job type of practice. From vocational schools, post secondary institutes and technical institutions to private welding schools, skills are achieved by strenuous work and eagerness to learn. Courses are very complex in structure; for instance, students must be capable of reading blueprints, understanding chemical reactions, and using mathematics and physics applications. Knowledge of computers is also closely related to the development of skills in welding schools, after all, some of the graduates will be making robots some day.

The justified question that rises here is connected to the job prospects for people who choose to attend welding schools. It goes without saying that most welding jobs involve working in very difficult environments, even outdoors when necessary, therefore, the relationship between work and remuneration should be truly rewarding to stimulate the employee. The best chances to get well-paid after the graduation of a training program in a welding school is in the aerospaces applications or ship and automobile building. Weldings is also an important part in the electronics industry as well as in the construction sector.

Many people choose certain welding schools after checking a variety of options available on the Internet. Good words are not a selection criterion, therefore, always ask for credentials when it comes to welding schools since not all of them are authorized to issue certifications. This is the main purpose of actually attending courses in the field, particularly since after a certain period of time you will have to pass other tests for the renewal of the same certification. The welding schools you can find promoted online also send quotes for their classes from short-term to long-term options. The choice is up to you!

Welding Forum

Muna wa Wanjiru asked:


With the increasingly demanding industrial needs, almost all sectors of activity depend more or less on welding; knowledge of the operation processes, capacity to read welding symbols from blueprints and advanced work skills are usually the main characteristics companies look for when hiring welders. But the most important issue is the way the employee safely manages to operate the welding machine. There are certain protective steps that need to be taken in order to make sure that the process is completed safely and efficiently. Here are a few tips that make welding a lot easier.

The place where the welding machine is located must be selected very carefully; the process must be carried on in a dry area where clean air circulates all the time. Such a measure is absolutely necessary since there are all sorts of chemical fumes that result from the technological process and they are highly risky for the operators’ health. In case open air access is not possible, the welding machine must have a special ventilation system installed in its very proximity, for the very same reasons that we have already stated. Furthermore, there should be no flammable substances anywhere nearby the welding machine: paints, solvents or other chemicals increase accident exposure.

The weld area needs to be cleaned prior to the application since any traces of paint, oil, rust or other impurities reduce the efficiency of the welding machine. The employee operating it must wear all the protective apparel required by the occasion: fireproof gloves, apron and a special helmet; all these prevent the exposure to radiation, sparks, spatters or fumes that result from the usage of the welding machine. Furthermore, all the settings of the welding machine need to be adjusted in accordance with the specificity of the metal that is going to be worked on; failure to do so could lead to burn outs or low arc penetration.

In case you have not made up your mind whether to buy or rent the welding machine, you can decide by setting a clear plan of action. The best way to do so is to answer a few simple questions related to the extent of the investment in relation with the expected results. For occasional welding processes, a rented welding machine is the most advantageous idea; you should only think about purchasing one in case the working time of the welding machine covers at least 60% of the activity period. Last but not least, a used welding machine should also do for someone who does not want to invest too much money in the business; second hand welding machines are usually very reliable due to the liability of the engine.

Tig Welder

Muna wa Wanjiru asked:


Not all metals can be processed without effort by welding procedures; there are some with very high conductivity properties that accumulate and generate heat almost instantly: it is the case of aluminum and magnesium. These metals came to be used only as late as the 1940s by means of special welding procedures known as MIG welding that has now been largely replaced by the process known as tungsten inert gas or tig welding. Presently, tig welding is used for almost all aluminum workpieces that require exemplary execution. The electric arc is formed between a tungsten electrode and the metal surface, the result being a very clean weld without any signs of oxidation whatsoever.

Tig welding is an automatic or semi-automatic process that allows the creation of continuous long and durable welds that wouldn’t be possible otherwise. The best gas shield required by tig welding is helium, argon or their mixture since, in association, these two chemicals increase the welding speed and the power of the process for deep workpiece usage. However, argon is welders’ favorite gas where tig welding is concerned; the explanation for this preference lies in the density of the gas – heavier than air – and its high quality coverage.

Why is the presence of the inert gas so important for tig welding? The flow of argon passes through the welding device simultaneously with the electrode, and during the process it acts as a shield against various contaminants present in the atmosphere that may affect one way or the result of the procedure. To put it in simple words, the argon keeps the air away from the weld area. Though tig welding can presently be used to create all sorts of very fine welds, steel and aluminum are still the metals the most widely associated with the tungsten inert gas procedure.

The pieces of equipment also need to be adjusted to the requirements of tig welding; for instance there are several types of joints especially created for the purpose. We could mention t-joints, corner joints, lap and butt joints here, some of them need a filler rod, some others don’t. The independent form is the butt joint where the pieces of metal are connected along the seams. The use of each the above in tig welding processes involves different types of seams and placings of the metal pieces. Good knowledge of process specificity is an absolute must here.

Welding World