10 Important Tips About Welding

Welding is the result of a combination of heat & pressure to melt materials & join them with a filler material. It is a process of fabrication which is a potentially dangerous one. It is part of industrial application. It can be done in many forms. Using different energy sources - gas flame, electric arc, laser, friction, ultrasound & electric beam - welding can be done. A basic welding application requires a power supply, electrodes, weld, rods & arcs, shielding gas & safety equipments like protective mask or helmet.

Protective equipments are the most important requirements for persons engaged in welding activity as an open electric arc/flame is involved; the probability of getting hurt is stronger. There is a high risk of getting burnt. To avert such a grievous wound, protective clothing like heavy-duty leather gloves & thick long-sleeved coveralls is used. Apart from burns, severe eye damage can also happen. Welders can escape this by wearing protective goggles, masks & helmets which have specially-designed dark or self-darkening lenses & faceplates. To reduce the negative effects of ultra-violet rays emerging from spark & arcs.

Welders stand the chance of getting exposed to toxic gases & fine particles. Smoke detrimental to breathing conditions is produced during welding. Gases & fumes which are capable of subjecting our body system to long-term ailments have to be avoided. When bottles of compressed gases are used, there is a potential risk of fire & blasts due to naked electric arcs & flames in close proximity. So, by segregating the areas of operation - like two different rooms for carrying out two dangerous activities. Such extremely-risky situations can be prevented.

Welding is a complex subject & a comprehensive analysis is a must. To get out of life threatening environment. The most commonly used easy-to-access welding operations are arc welding, gas welding including TIG welding & MIG welding.

Arc welding is a process which employs a power supply to create a welding arc between an electrode & a base material to melt the metals at the welding point. DC current or AC current can be used. Consumable or non-consumable electrodes can be put to action. A kind of inert or semi-inert gas, known as a shielding gas and/or a filler material have to be used to protect the welding region. During MIG & TIG welding, continuous & consumable wire electrodes are passed through a welding gun. Constant voltage & DC power are normally used in MIG/TIG welding. They were originally used for welding aluminums. Of late, the gas metal arc welding is applied to steels also. MIG welding can be understood easily. Long-duration welds can be made without any break in the middle. Post-weld cleaning is minimized to a great extent. The minus points are oxidized weld deposit, unstable arc, & weld porosity. TIG welding permits welds o superior standard, with or without filling metal, good control of heat & low distortion.

The following are the common errors:

• Failure to clean the parts & weld surfaces properly. Any paint, dirt & similar materials will result in improper weld.
• For gas welding, wrong gas is used sometimes. Cheap gas should be avoided. A mixed gas brings good results.
• Wrong polarity results in a bad-looking weld bead.


• Wrong contact tips sizes.
• Insufficient travel speed - too fast or to slow.
• Insufficient shielding. Eg: Wind not stopped while welding is going on.
• Welding too cool on a bigger material - which results in lack of fusion.
• Under buying - selecting very small welding machine.
• The wire feeder's wear components like liners, contact tips & other parts - not maintaining properly.
• Filler material not matched in a proper way. ie; The right tensile strength is lacking.