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Posts Tagged ‘Introduction’

Proper information on the welding process is necessary for those who wish to learn welding and also for those who wish to improvise their welding skills. Most often people are interested to begin a career in welding and some others would like to take their career to a new level. Basically welding is the process in which base metal parts are melted and joined using a filler material which has the same characteristics of the parent metal. Welding is conducted using different sources like gas flame, laser, electric beam etc.  There are different types of welders namely Arc welders, MIG welders, TIG welders and Gas welders. Among these types, TIG welding is considered as one of the most difficult type to learn and master.

TIG welding is considered as the most flexible type of welding as it can blend all conventional metals like Carbon and low alloy steels, stainless steel, nickel alloys, aluminum, magnesium, titanium, cobalt, and copper alloys. TIG welders otherwise known as the Tungsten Inert Gas Welders uses an arc which is created from non-consumable tungsten. The heat for the welding process is generated using electric current. This type of welding has many advantages like its high amperage allows welding of metals with great thickness. Other advantages include the concerns related to purity of metal and cleaning.

It is not at all an easy task to master TIG welding. Generally all the other welding methods allow the welder to simply manage with one hand. But this method requires intense attention and focus. The process involves great amount of concentration as the welders use both the hands to manage the welding area while adding the filler material to the surface. Moreover, it is highly equipment centric. For protecting the welding area from airborne contaminants, the welding uses inert gases such as argon. Due to this process, the welding would be clean and precise.

Right amount of precautions that are usually taken while performing any welding methods are always advised in TIG welding as it could be dangerous if performed carelessly. The welding brings in large intensity of light and if the eyes are directly exposed, it results in the burning of retina called as arc-eye. A face guard to shield the eye from direct exposure to intense levels of light is a must for all the welders. The whole body should be properly covered during welding as the exposed light carries UV radiation that is harmful to the skin.

TIG welding is usually used in the automobile and space craft industries since the finished materials and alloys created using the welding method are highly corrosion and cracking resistant even over a long period of time. Like all other types of welding, the TIG welding also becomes easier with practice. For a beginner, it is suggested that he must practice with scrap metal stock before attempting any real projects. This type of welding is highly sophisticated and is usually expensive than the other types as the beginners hesitate to buy the welding kit. However, the high price is worth as the product carries a number of benefits compared to any other.

Spot welding is a process contacting metal surfaces joined by the heat obtained from resistance to electric current flow under pressure exerted by electrodes. Classically the spot welder sheets are in the 0.5-3.0 mm thickness range. The gorgeous characteristic of spot welding is a lot of energy can be delivering to the spot in little time and permits the welding to take place without unnecessary heat to the rest of the sheet.

Applications

Spot welder is typically used for particular types of sheet metal. Spot weld heat flows into the immediate metal and easily identified on many sheet metal goods. Aluminum alloys can be spot welded but large amount of thermal and electrical conductivity requires higher welding currents. Spot welding is used in the automobile manufacturing industry, used about universally to weld the sheet metal to shape of car. Nickel-cadmium is one more application of spot welding, straps in order to make batteries. The nickel-metal-hydride cells are connected by spot welding slim nickel straps to battery terminal.

Processing and Equipment

Three stages for Spot welding; the first involves the electrodes creature bring to the facade of the metal to applying a small amount of pressure. Workpieces is welded two materials together to conduct electricity. Removing current from the workpiece cooled by the coolant holes in the center of the electrodes. In spot welding mechanisms, water and brine solution is used as coolants.

Tool Styles

In spot welding, electrodes can used differ really with different applications. In radius style, electrodes are used for high heat applications with a truncated tip for high pressure. In offset eccentric, electrodes reaching into corners and small places to finish offset truncated for success into the workpiece.

Effects

The effect of spot welding process is tends to harden material, reduce material strength, and stretch the material. The physical effects are including internal cracking, exterior cracks and terrible appearance.

Electrical notes

The basic spot welder consists of a power storage element, a power contribute and the welding electrodes. The power storage elements allow the welder to distribute high immediate power levels. The energy storage element is useless during the power demands are low. The welding transformer steps down voltage and steps up current. A basic feature of the transformer to reduce current intensity and the switch must handle. The transformer’s secondary circuit has welding electrodes and control box to handle the switch and examine the welding electrode energy. A spot welding machine usually consists of instrument and electrodes mechanisms for making and holding contact. There are two functions of Tool holders, to grasp the electrode firmly in place and support water hoses for cooling of the electrodes.

Safety Factors

Spot welding can be extremely dangerous due to use of huge amounts of voltage and heat. Welders always sure to hold tightly the electrodes, protect eyes from the intense light given off during welding process and protect hands due to workpiece can get very hot throughout welding. Bring all safety protection required earlier than, throughout and after spot welding.

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Plastic welding and spot welding – both are almost similar to each other. There is a difference noted. In plastic welding, heat is supplied through convection of the pincher tips, instead of conduction. The two plastic pieces are brought together. At the time of welding, a jet of hot air is liberated. This melts the parts to be joined along with the plastic filler rod. As the rod starts melting, it is forced into the joint and causes the fusion of the parts.

Plastic identification is the first point to be noted in order to choose a suitable plastic welding rod. A plastic welding rod or thermoplastic welding rod is of a constant cross-section shape. Using this, two plastic pieces can be joined. It may have a circular or triangular cross-section. Porosity of the plastic welding rod is an important factor. Air bubbles in the rod will be created due to its high porosity. This is responsible for decreasing the quality of the welding. So, the rods used must maintain zero porosity. Otherwise, they should be void less. Products like chemical tanks, water tanks, heat exchangers and plumbing fittings are manufactured by using the technique of plastic welding. By adopting this technique, money can be saved.

Using plastic welding, two plastics can be welded together. This type of weld is performed on children’s toys, lawn furniture, auto parts and other plastic equipments which are used daily – both for domestic and commercial purposes. In order to join the thermoplastics, when they are heated an under a particular pressure, this type of welding is employed. In normal practice, using filler material, the pieces are joined together. There are certain occasions wherein filler material can be avoided. Generally, plastic is not durable and has a shorter life span. Natural elements like cold weather, ultraviolet radiation from the sun or continuous exposure to chemicals causing contamination, will create damage to plastic products. Plastic can be subjected to damage if it is hit on a hard surface. But, as the price of new parts is high, it is preferred to repair the existing products.

As there are different types of plastics, we must know which one we are working with in order to find the exact welding material to be used. We must know the difference between thermoplastics and thermo sets because it is not possible to weld thermo sets. If you use the wrong welding rod for the plastic to be repaired, bonding will not take place. As materials like polyolefin’s have a lower surface energy, a special group of polyolefin adhesives has to be used. When you are repairing plastic, there are usually two types of defects – a crack or a broken part. In the case of a crack, there is a particular stress affecting the inside of the material. You have to repair the crack and you should not continue through the piece.

There are many types of plastic welding.

Hot gas welding uses a welding gun which has electric heating elements. They produce heat f hot gas. Hot plastic welding uses a hot plate place between the two surfaces which are to be joined. In order to weld two pieces, ultrasonic welding uses a high frequency acoustic vibration. After subjecting them to high pressure, they are exposed to the vibrations until the weld is completed. Spin welding, where friction is employed to weld two cylindrical parts. These parts are rotated. The rotation stops at a particular point and the weld is completed. Vibration welding exposes the pieces to a frequency called amplitude. The two pieces are subjected to pressure due to which a friction is created which generates heat.

A diesel generator is a combination of diesel engine with an electrical generator to generate electric energy.

Most people know that diesel engines in automobiles provide higher mileage, making it an obvious choice for heavy-duty transportation and equipment. Diesel is priced heavily when compared to gas, because it has a higher energy density and more energy can be extracted from diesel when compared to the same volume of gas. Diesel fuel has heavier, oilier and has a higher boiling point when compared to gas. When you compare petrol, gas and other fuels, diesel is least flammable. When compared to gas generators, this generator requires less maintenance. Being rugged and reliable, it can work for long hours at a stretch. Modern diesel generators can overcome noise issues. Onsite fuel delivery is available. These generators are used in many industries like mining, telecommunications, marine and agriculture applications, hospitals, industrial plants and commercial buildings. Although they are built for large loads, modern diesel generator is designed to comfortably handle small loads without wet stacking. These are available in single phase and there phase power generators.

You can find different types of diesel generators in the market. Small portable diesel generators range from 1kva to 10kva, while larger industrial generators range from 8kva -30kva for homes, small shops & offices up to 2000kva used for large office complexes, factories and power stations. These are used as a back up source for outdoor recreational or camping activities. Diesel generators have certain important features like: engine block is an important part of the diesel generators and the four cycle, liquid cooled model helps to improve the life of diesel generator producing less noise. There is little difference between air cooled and liquid cooled diesel generators. Air cooled engines require a tremendous amount of air. Liquid cooling offers a quieter operation and more even temperature control. There are various brands available in the market, but the wise decision would be to choose a generator from the leading brands as they come with the right configuration and warranties.

Diesel generator is most reliable and maintenance-free of all types: no ignition systems, carburetors, nor spark plugs. The fuel can be stored in large tanks; it is less flammable than other fuels and is the safest fuel to store. Diesel generators are widely used in places where grid is not available or as emergency power source if the grid fails.

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