Welder World Blog

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Don’t worry too much about how your welds look at first:
* While you’re improving electrode control, you’ll be learning more about different welding job situations.
* Plus I’ll tell you WHY it’s important to have good rod control.
* After you read these tips, THEN you can practice your welding rod control techniques.
* Whether you swing a golf club or a bat, if you don’t practice in correct ways, the results can be at least EMBARRASSING!

Let’s talk about arc pressure and gravity:
1) Arc pressure is produced by the voltage from the machine as it’s pushing the molten metal outwardly.
2) The pressure will vary depending on machine settings, rod size, & the amount of arc gap.
3) Gravity not only effects the direction of the molten metal, but also it’s going to try to make your puddle drip.
4) If you’re arc welding in a flat position, you mainly just worry about keeping the rod at right angles to the work-pieces, & tilted away from the puddle, to help control the puddle & the slag. (And that will help you to SEE THE PUDDLE!).
5) If you’re going to weld in a vertical position, you need to aim the arc up-ward to preheat the metal & to help keep the puddle from dripping.
6) At the same time, in vertical welding, you no longer need to worry about slag, because gravity is keeping it out of the way.
7) For horizontal positions it’s a lot the same. Gravity will try to drip the weld, so you aim the arc upwardly.
For overhead jobs you keep the rod nearly straight up for the same reasons. You don’t want to do any weaving in overhead welding, instead just use straight “stringer” beads.

Pipe welding:
* Pipe welding is rather unique, in that it involves all positions as you go around it. You will gain real electrode control experience in pipe welding!
* Horizontal welding on pipe can be tricky too, because you need to keep changing the rod angle as you go around.
* Save overhead welding practice for last. Get used to ELECTRODE CONTROL & amp settings in the easier welding positions first.

General tips:
* Learn to keep the arc length as steady as possible, plus keep the rod angle steady.
* Weld in a straight a line. This helps to give your welds to look better, and to give them more strength.
* Use both hands to steady the rod. Either place both hands on the rod holder, or one hand on the rod itself, until it gets too short (or until the rod gets too hot).
* Work on a steady speed to keep a uniform puddle shape. An oval shape is good, but don’t let it get too pointed. A round shape may be too wide, unless you need a wider or heavier bead for the job you’re doing. You’ll soon be able to judge that your welding speed is right for the job size & situation.
* Finding a good amperage setting for the job at hand, will help you to concentrate on getting a good weld, & not be fighting sticking rods, or having the rod burn through the work-piece.
* Learn to hesitate slightly at the start of your welds to ensure that the “puddle” forms sufficiently.
* Also pause a bit, at each side of the bead, when you’re doing a weave weld, to make sure there is good penetration.

REMEMBER, Don’t worry too much about how your welds look at first! Now start practicing!

Joel Ort of Miller Electric Mfg. Co. shares his tips for MIG welding success. Placing the focus on MIG technique, Ort’s useful comments are applicable for many garage applications involving farm and automotive repairs. Topics include: simple setup, butt joints, T-joints, lap joints and horizontal, vertical and overhead welding positions.

Related Welding Positions Articles

The trainings being conducted by Tektone Global Technologies Foundation, Inc. and its partners are helping solve the mismatch between the skills possessed by applicants and the skills required by employers here and abroad.

This is what Albay First District Cong. Edcel C. Lagman told the graduates, parents and guests during the First Commencement Exercises of the Tektone Global Technologies Foundation, Inc., Eco-Trail Society Foundation, Inc. and Southern Luzon Technological College, Inc. held on April 18, 2009 at the AQ Dome, Aquinas University, Legazpi City.

Pointing out statistics and results of studies conducted by the National Statistics Coordination Board, the Department of Labor and Employment and the Technical Education and Skills Development Authority, Lagman noted how the lack of conformity of competencies possessed by new graduates with those required by employers make it very difficult for young people to find jobs amidst significant demand for workers.  He said this trend, if left uncheck, could become more severe as the world face a global economic slowdown.

Lagman congratulated the families of the trainees for supporting them in choosing the right courses – courses that have real demand in the labor market.  “Ang hinahanap ng mga employers ay skills hindi diploma na nakasabit sa dingding,” he said quoting Technical Education and Skills Development Authority Director General Sec. Augusto “Boboy” Syjuco.

Lagman also expressed his appreciation to Sunwest Group of Companies Chairman of the Board Elizaldy “Zaldy” Co for spearheading training programs that directly address skills gaps and ensure employment of graduates.  Both the Tektone Global Technologies Foundation, Inc. and Eco-Trail Society Foundation, Inc. belong to the Sunwest Group of Companies.

Eighty trainees in heavy equipment operation and 39 trainees in specialized welding graduated from their courses in Tektone Global Technologies Foundation, Inc. and Eco-Trail Society Foundation, Inc. during the graduation exercises.  They were joined by 350 other graduates in business process outsourcing from Southern Luzon Technological College Foundation, Inc.

Lagman is an ardent supporter of technical-vocational education and training from the beginning of his service as congressman of the First District of Albay until now.  He is responsible for the establishment of a string of public training centers and technical-vocational schools in Albay and the promulgation of government training and scholarship programs in technical-vocational education and training.

Lagman sponsored the second batch of trainees in specialized welding under the Eco-Trail Society Foundation, Inc. by providing PhP5 million pesos to cover the training expenses for more than 100 persons.

The second batch of trainees is being conducted in cooperation with the City Government of Legazpi under Mayor Noel E. Rosal.

About

TEKTONE Global Technologies Foundation Inc. is a technical-vocational institution in Bicol that is the premier training provider of globally-competitive skilled workers in construction, tourism and related sectors. It provides competency-based training and outsourcing services for welding and heavy equipment operation.

Find More Welding Jobs Abroad Articles

Gas Welding is alive and well!
* If you want to create artistic projects, many people will choose gas welding exclusively.
* At some point, most arc welders will want to, or NEED to use gas welding. I’ll help you get started. Then YOU need lots of practice!

Seriously, practice is CRITICAL for running great beads.
* If you’re doing artistic stuff, you’ll want it to LOOK great.
* Eye-hand coordination gets tougher because you’re doing more multi-tasking then arc welding.
Being able to DIRECTLY be shown details about how to do special jobs like gas welding is the BEST way to get started. (By WATCHING some else gas weld).

Here’s the “scoop” for this article:
1) I’ll give you a brief introduction to the gas welding world…
2) Then I’ll hit on some safety tips…
3) Next the equipment itself…
4) Getting started:
* The flame.
* Adjustments.
* Angles.
5) Filler rod, tacking, the puddle, problem solving.
6) Brazing Tips.

INTRO:
* Gas welding in this page refers to oxygen-acetylene welding of metals.
* Your are actually WELDING two pieces of metal together, wheras brazing doesn’t melt the parent material, just the material used to join the pieces.
* The torch itself needs to be able to melt the metals being used: filler rod, & “parent metals”.
* Having an oxygen-acetylene torch around enables you to not only WELD, but also to cut the materials, heat & bend materials, & loosen tight-fitting materials via heating.
* Safety is paramount! You are working with extremely hot & potentially explosive materials!

SAFETY STUFF:
SERIOUSLY gas welding can really be fun, interesting, & profitable!
BUT:
* The tuned gas flame can exceed 6,000 F.
* Un-protected eyes can be fatigued & permanently harmed in a short time.
* The acetylene tank could explode under certain conditions: dropping, in a fire, from an arc or torch flame penetrating the casing, etc.
* The oxygen tank starts with 2000 PSI & can literally go like a rocket if the top valve assembly breaks off.
* Hitting something already burning with the high pressure torch valve can really accelerate the fire.

So, be careful!

GETTING STARTED:

The Flame:
* Set the gas and oxygen pressures MUCH lower than for cutting.
* Some gas setting charts call for the 02 & gas pressures to be the same as the tip size being used: tip size 1 = 1 PSI for gas & O2.
* Tip size 5 = 5 PSI for gas & O2, etc.
* I simplify things even farther! I just set both pressures at 10 PSI then crack the valves open at the torch handle to where I need them to be. Just start EASY & work them up to the capabilities of the tip. (or just do it as above).
* Also, tip sizes vary for the size metal being welded: Tip size 1 = 1/16″ metal and tip size 5 = 1/4″ as examples.
* It really isn’t hard to figure out if the tip your using is too small or too big for the job. (Too small won’t get everything hot enough, & too large will tend to blow everything away).
* Crack open the gas & light it right away.
* Crank up the gas till it separates from the tip then back it off.
* Hit the O2 until the blue flame first gets short & bright. This is a “neutral flame”, used for most jobs.

Note that the torch tip & the filler rod should be about at a 45 degree angle.
*Too steep can make the penetration too deep & not pre-heat / too shallow can cause too little penetration.

Let’s do it:
* Starting out, it can give you good practice to just put the flame on metal without a filler rod. This helps you get used to the process without worrying about the filler rod too.
* Heat the metal till there’s a puddle, then begin moving the flame to create a bead.
* Get the blue part of the flame nearly touching the metal.
* Move in a circular or semi-circular fashion to make it into a bead.
* Aim the flame in the direction you’re trying to make the bead. (forehand welding).
* Don’t get ahead of the bead or it can make it not hot enough at the puddle.
* Do this for a few times before using a filler rod.

Introduce a filler rod: (usually the same diameter as the pieces that are being welded).
* start the same way as above and keep the rod at a 45 degree angle also.
* Dip the rod in the puddle frequently, but try not to heat the rod with the flame. (heat the puddle, not the rod).
* Practice running straight beads then work up to following curved paths. (some schools have you write your name with a gas welding bead).

THEN PRACTICE till you can run decent looking beads.

Note that you should be tacking pieces together at least at both ends of where you’re welding, to prevent moving of the gap.

Problem solving:
* Your flame is fluctuating: gas pressure or supply may be low.
* Popping sound: Hot tip, plugged tip, pressure too high.
* Flame stops: 02 pressure high.
* Whistling noise & the flame backs up into the torch: (backfire), 02 or gas too low, the tip is clogged or dirty, or the tip touched the puddle.

BRAZING:
* Many things are similar about gas welding and brazing: but remember that with brazing you aren’t melting the parent metal, just the brazing material (such as brass).
* The brass and the parent metal MUST be clean and hot enough for there to be a good joint. (Use flux! In a can, or coated rods).
* Think of soldering, if you don’t get everything hot enough, it might come apart (or not be a good electrical connection).

Now GET BUSY PRACTICING!

This was a just a BRIEF description of the gas welding process.

Good luck to all you ladies & gents!

next few weeks at work i’m planning on turning a bunch of steel and aluminum bars (from the scrap heap) into different sized metal shelves using a TIG welder. i haven’t used the welder in awhile but i planned to be supervised by an expert. So my question is really asking for tips/pointers into putting a metal shelf together.

I understand that steel and aluminum will not combine.

The shelves will be used to hold computers and monitors and other necessary equipment for a combustion experiment.

Is there a systematic process (for a shelf specifically) into assembling the bars? How will i be able to clamp it down if the bars are going to be different widths and at right angles? Once the frame is built, there may be an option to weld metal boards, how can that be done? When will a tack weld be more useful than a line weld?

This is the first time that I will be making metal shelves, so any extra tips beyond the questions posted will benefit me greatly.