Welding - New technique of combine metals

February 7th, 2010

Welding is referred to joining of two pieces of metal. This can be done by melting iron pieces and add filler material let it cool which make it harder. Welding can be done in air, water and outer space.

Types: Arc, metal inert gas, tungsten inert gas welding.

Arc Welding: It is like welding process using electric arc between two pieces and electrode. The electrode either is a rod or wire. There are five common types of arc welding method. They are shielded metal which is using for metals, gas metal, flux core, gas tungsten and submerged arc welding which is using for steel plate.

Metal Inert Gas: Metal inert gas also called as gas metal arc welding. This process is easiest among all. It is automatic or partially automatic process, where the wires are connected to direct current act as electrode to join the work pieces of metal. It has the ability to combine the non-ferrous metal. Two types of MIG are conventional and pulsed MIG. Conventional MIG uses direct current power and pulsed MIG uses alternative current power.

Tungsten Inert Gas: It is also called as gas tungsten arc welding. Here the types of gas used for welding are argon and helium. The advantages of these two gases are speed and easily perforate. Using TIG welding you make joints like corner, lap, butt and t-joint. Corner joins the two corner pieces of metals. Lap joins the top and bottom piece. T-joint is used to join the parallel piece of metal to perpendicular metal.

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An Overview for Manual Metal Arc Welding

February 5th, 2010

Manual metal arc welding technique was discovered in Russia during 1888s. This technique of welding is also termed as shielded metal arc welding (SMAW) or stick welding. The process of welding first starts by striking an arc between the base materials and the consumables electrode rod. These rods are made up of steel and it is covered with a flux and the weld area is protected from the oxidation and contamination during the welding process.

During the process when an arc is struck between the electrode and work piece materials the surfaces are melted down into the weld pool. And a coating is formed around the rod by melting down the flux. This melting of coating forms gas and slag to cover the weld pool from the surrounding environment. The speed of welding is relatively slow in this process because more often the welder has to replace the consumables rod and has to chip down the weld bead once the welding is over. This process of welding can also used to
weld other metals too.

The stability of arc formed, depth of penetration, the amount of metal being deposited totally depends on the position of welding and amount of coating provided on the electrode during the welding.

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Welding – Power Generating Equipment

February 4th, 2010

Welding machines plays vital role in various industries. A method of combining two or more materials is termed as welding. Most part of the machines is joined by this kind of process. The diesel generator is used for producing electricity. Let us see the diesel generators and welding instruments in detail.

Diesel Generator: A part of diesel engine, generator, and supporting devices such as control systems, starting systems, circuits, base, silent generator and canopy are grouped to form a diesel generator. The silent generator is the main part of diesel generator because it is portable in size, easy to use and set up, user friendly. It is used in homes, industries and offices. In today’s market two types of silent diesel generators are selling:

Types: 5.0KW - 6.5KW and 10KW - 50KW diesel generators

  • 5.0KW - 6.5KW: The three classification of 5.0KW - 6.5KW are economy, super and deluxe generators.Economy: It provides ATS Switch, Pre heater, Remote control and UL panel.

    Super: Super provides throughput for 8 hrs, 6500W, 9 HP diesel engines, and full power panel.

    Deluxe: It is a fuel save, low noise, actions are controlling by remote system.

  • 10KW - 50KWIt is classified into 15000W, 18000W, 22500W, 33500W and 40000W.

    Its characteristics are power saver, fuel saver, produce low noise, it can
    be used in construction and remote areas.

    The peculiar feature of 22500W is dynamic current battery, 1 year or usage of 1000 hours warranty.

Welding:

  • Various forms of process are involved in welding, namely arc, gas, resistance, energy beam welding, Metal inert gas, Tungsten inert gas, Shield metal arc welding.
  • MIG is also termed as feed welding.
  • Gas welding involves the process of oxyfuel welding. In arc, power supply is important. It may be either direct or alternating current.
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Oxyacetylene Welding Overview

February 3rd, 2010

Oxyacetylene is also known as gas welding. The technique used is to mix two gas components namely oxygen and acetylene in an equal ratio and with the help of hand-held torch or a gas blow pipe a humid flame is produced with the temperature being around 3,200 degree Celsius. To adjust the excessive outflow of oxyacetylene flames change the volume of mixing ratio of two gases from oxygen to acetylene. The settings that are used for adjusting flame are neutral, oxidizing and carburizing.

As the ratio of mixing the gas is equal welding are generally done in neutral flame setting. In the second type of setting the outflow of oxidizing flame is obtained by increasing the flow rate of oxygen. And in the third setting carburizing flame is obtained by increasing the flow rate of acetylene.

As the amount of heat generated in Oxyacetylene welding process is high, it is best suited to weld the steel. The other gas components such as propane, hydrogen and coal gas are been used to join the lower melting points of non-ferrous metals and it can also be used for brazing and silver soldering. In this welding technique as the gas components are stored in steel cylinders at a specific pressure the equipments are friendly to handle and easy to use.

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Role of Welding Inspector in Welding Industry

February 2nd, 2010

The job of welding inspector comes with lot of responsibility and dedication in ensuring the quality and safety of welded work in various structures.

  • Quality of work done by the welders is tested based on the variables such as; the process, metal type and thickness, filler metal type, electrical parameters, joint design and welding position, noticing and documenting errors or faulty work, and recommending corrective measures.
  • The most important test which they conduct is ultrasonic nondestructive testing, where a check is performed on the safety of welds in structures and for any defects and cracks that can jeopardize the safety of the structure. And to conduct some of the necessary welding tests, such as checking for cracks and testing welding strength, an inspector may need to use flashlights and magnifying glasses.
  • They are also responsible to check whether a welding joint has any cold welds or any undercuts. Today many companies who are in the field of metal work are relying on welding inspector to successfully operate their business.
  • Their daily work involves preparing reports that document the work that has been done, the quality of that work and whether or not a welding job has been satisfactorily completed as per certain industrial guidelines that differ from one industry to another.
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MIG Welding Guide

February 1st, 2010

Mig welding is popularly known as feed welding. Metal insert gas or Gas Metal Arc Welding (GMAW) or Metal Active Gas (MAG) is one of the fastest welding techniques. The process of welding is semi-automatic or automatic arc in which a continuous and consumable wire electrode and a shielding gas are fed through a welding gun. It is mostly utilized in high production welding operations. This welding can be carried on metals such as carbon steel, stainless steel, aluminum, and copper can be welded with this process in all positions by choosing the appropriate shielding gas, electrode, and welding conditions. Due to its versatility and speed it is commonly used in automobile industry. A flow of an inert gas usually Argon gas used is passed through the welding gun at the same time as the wire electrode. The Inert gas acts as a shield, keeping air borne contaminants away from the weld zone.

Following are the advantages of MIG

  • It is highly productivity, because welders don’t have to stop to change rods or chip and brush the weld frequently.
  • The process is easy and makes great-looking welds.
  • Almost there is no cleanup required.
  • This process of weld can be carried on stainless, mild steel, and aluminum.
  • It can be weld in all positions.

The welder has to follow safety tips while welding and protect himself by wearing a welding mask, wear flame proof coats and gloves and fully covered leather shoes.

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Tig Welding Overview

January 29th, 2010

Tungsten insert gas welding is popularly also known as Gas tungsten arc welding (GTAW). You can protect the welding area from getting contaminated with the help of shielding gas which is insert gas.

Tig welding is more widely used to weld the thin sections of stainless steel and non ferrous metals such as aluminum magnesium and copper alloys. This welding process grants the operator to have a greater control over the weld when compared with other welding procedures such as shielded metal arc welding and gas metal arc welding. Though this welding process is very slow but it provides high quality welds.

Tig welding can be carried on all positions - flat, horizontal, vertical or overhead. Perfect for roll cages and inside confined areas too. Filler rod is one of the most important aspects in this welding process.

Equipments required for tungsten insert gas welding process are welding torch utilizing a non consumable tungsten electrode, a constant-current welding power supply, and a shielding gas source.

During this welding process an arc is formed between a non-consumable tungsten electrode and the metal being welded. Gas is fed through the torch to shield the electrode and molten weld pool. If filler wire is used, it is added to the weld pool separately. Welders have to be careful while doing this procedure.

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WELDING OVERVIEW

January 28th, 2010

In the recent years, welding has gone through drastic changes in electric arc, laser beam, gas flame or electron beam welding. Latest developments are going on in robot welding. Welding is one of the important tools in construction, manufacturing or garage shop. The person who does this job has to take lots of safety steps and follow them wisely and if he fails to do so it can be very hazardous for him and others too.

Today different methods and techniques are carried on in welding process. Most of the equipment that we use in our day to day life or which we come in contact often is mostly welded in some way or either. Welding is a technique to join two or more pieces to make them look into one single piece. Welding process has to be carefully carried on because chances of mishaps are frequent due to carelessness or lack of knowledge in equipment handling or usage or misuse of available equipments. While welding, protect your eyes with the help of goggles and helmets. To protect other parts of your body, wear flame proof coats and gloves.

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To weld Titanium

January 27th, 2010

The process of Welding-titanium and its alloys must be carried with lots of safety measures because these materials are very reactive to contamination from atmosphere gases. The process of welding this material is quite different from other ferrous materials.
Steps to follow:

- Assemble the materials, and clean the material which is needed to be joined. To clean its grit and surfaces of grime you can do it with the help of rag, water and soap. And before buffing for smooth and dry, clean all blemishes and scuffs. By using alcohol swab you can prevent the outside chemicals causing harm to the surfaces.

- Before using argon gas it should be checked whether it is pure or not because small amount of impurity can cause damage to the titanium materials. To check the purity of the argon gas start flowing it before it is set in high frequency. If there are no signs of discoloration after few movements of its flow then it is pure argon gas.

- Now start the welding process with the argon gas flowing in high frequency. If there are any signs of swirled pattern emerging then your argon flow is too high. Reduce the flow level.

- During the entire welding process ensure that there is flow of shielding gas. Do not compromise on color and the integrity of the material.

- Handle the material carefully Use only cotton gloves to handle. Gloves already been used can cause damage to the material.

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Projection Welding Advantages

January 22nd, 2010
  • Simultaneously we can make any number welds in heavier materials easily.
  • Projection welds can be made in metals that are too thick to be joined by spot welding.
  • When you compare with spot welding, projection welding interferes less scale, oil, rust and work metal coatings.
  • Lower Electrode Maintenance.
  • Less Welding Current Required.
  • Projection welding life is longer than spot welding.
  • Lower amount of current and pressure needs to joint metals.
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