Archive for January, 2009

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The Basics of Metal Core Wire

Thursday, January 29th, 2009

Metal core wire is a fairly new type of wire that some welders are using for specific projects. This is a tubular electrode and it has a core with a variety of powdered materials and a metal sheath.

When comparing solid wire and tubular wire it is easy to see why some welders use it for specific project. Part of the difference between the two is where the welding current resides. On solid wire the entire section will carry the welding current while with metal core wire the current is only concentrated on the sheet that is outside. The metal powders are granular so they are less conducive to the weld.

The welder will get a more bowl shaped arc when using tubular wire and it will create a finer melting of the metal and the weld pool will be less turbulent.

Why Welders Use Metal Core Wire

This type of wire is more cost effective than other wires because for ever pound of weld metal they save between $100 and $200. This wire has little splatter and there is no slag associated with it. Using burn-through a welder can bridge partial gaps between metals which cannot be done with other types of wire.

When purchasing metal core wire it will be a little more expensive but in other types of wires, filler metals make up at least 10% of the cost. With this wire the welder will have an increase in productivity which balances out with the cost of the wire.

Welders can also weld thinner materials at higher amperages when they need to without worrying about the metals burning through each other. Larger electrode diameters can be used since the metal core wire is made up of metal and granular powder.

Applications for Metal Core Wire

There are a variety of projects that are best done with metal core wire. Some of these include:

  • When you have a project that you would normally use single wire with but the weld is more than 3 inches long and you will only make single pass over the metal.

  • When you are in the horizontal or flat position and you are using spray transfer.

  • When automatic welding is being used or where robotics will make a multiple pass through the metal.

Metal core wire will give a strong fusion especially when you want to bridge a gap or help to eliminate a cold lap.

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How To Buy a Plasma Cutter

Tuesday, January 27th, 2009

Many people go to the store for a welding machine and they know exactly what to buy. When you are going to buy a plasma cutter there are more issues to take into consideration because of the way it is made.

When you are looking for a plasma cutter the first thing to consider is what you will be cutting most of the time. Plasma cutters are generally rated by how thick the material is that you will be cutting so it is important to make sure that you do not have a machine that will undercut the metal you are working with most of the time.

As you look at plasma cutters study each make and model to see what they do and how they do it. You will choose one that will fit your needs for what you want to do. One way to do research on this is to go to online forums that discuss this topic. People will talk about what they bought, what it does, why it works for them and more.

What Brand To Buy

This is not something that can be answered for you because you will have to decide based on what you need. There are four major brands: Miller, Hobart, Firepower and Hypertherm. Each of these is a good brand but they all have different prices for lots of different plasma cutters. You will need to shop around and comparison shop before you buy.

The Power of the Output

Each plasma cutter will have a certain amount of power it puts out depending on the thickness and the type of material that you are going to cut. The thickness will also tell you the right sized nozzle opening that you will need and it will determine the type of gas, the amount and the air that you will need to use it.

The way to figure this out is to think about the type of metal you will be working with most often and then check the cutting capacity that the machine has that you want to buy. Also, check the cutting speed because some plasma cutters are faster than others which cuts down on the time it takes you to produce your work.

Finally check the amperage that you will need. Some plasma cutters are able to use multiple currents and this may be important to your needs.

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Plasma Cutting Tips for Successful Plasma Cutting

Sunday, January 25th, 2009

There are many ways to weld and when you need high heat plasma cutting is your best way to do it. You will find that plasma and the plasma arc process has been refined so you can get a better quality cut at higher speeds with a lower cost. You can also find that gouging and piercing will go a lot smoother.

Generally speaking plasma cutting is a simple technique to learn though the process seems complicated. Plasma cutting is also safer than using oxyfuel because there are no flashbacks or dangers from flammable gas like there is in oxyfuel gas cutting.

When you have a metal that you want to cut and it is a good electrical conductor, plasma cutting is the best way cut it.

How To Set Up the Plasma Cutter for the Best Cut

When you first start the cut the torch should be as close as you can get it to the base metal’s edge. Next press the trigger so you can start the pre-flow air and light the pilot arc. When you see that the cutting has started, control the torch so that it moves slowly across your project. You may need to adjust the speed to keep the sparks under the bottom of the metal. Watch the metal because if you do not see sparks under the bottom then you are not getting through the metal. If this is the case, slow down your movement and check the amperage of the plasma stream; make sure that you are holding it at an angle.

As you are finishing the cut, put the torch at a slight angle or pause it so that it will automatically finish the cut.

How To Make A Perfect Gouge

To do this you should place the torch at a 40 degree angle to the base metal. As you see the cutting arc igniting, make your arc a short distance from your work. You may have to adjust the length of the arc and the travel speed so that you are able to control the gouge. You do not want to cut it too deeply at first because you may have to do more than one pass if you are attempting to go through thick metal.

Plasma cutting is a skill that needs to be practiced just like any other welding technique. With these tips you may find that your practice goes smoother.

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Careers in Welding

Thursday, January 22nd, 2009

With the current economic crisis it can be difficult to know what career to go into if you are a new or returning college student. In many situations learning a trade like welding can be worth the time. It can insure that you will always have a job if you are good at what you do.

Welding can be done in a variety of settings which may surprise you. Most people know that the aerospace, automobile and shipping industries require welding but you can also be a part of the research and development of new ways to weld. You could also be involved in sales and repair or you might be working in a laboratory.

Job Outlook For Welders

According to the Department of Labor welding is growing slowly. However, there is always a need for people who have mastered the trade t and who can do the job well. As an example, the O*NET which is the online database that lists jobs, shows all types of welding “in demand.” This means that people are looking for skilled welders.

Tasks You Will Do

Some of the tasks you will need to know how to do include:

  • Being able to weld in all types of positions.
  • Be able to operate safety equipment and be knowledgeable about how to stay safe.
  • Know how to strike arcs and start power supplies.
  • Monitor welding processes like burning and fitting so you do not overheat the work.
  • Be able to measure work pieces, measure them properly and check them for defects.

In addition for some types of welding jobs you will have to have a steady hand, be able to see details at close range with a safety helmet on, have manual and finger dexterity and be able to communicate with others.

In 2007, the average entry level welder made about $15.51 an hour and made about $32, 270 a year. You also need to know that many welders work very long hours and they work in hazardous conditions.

Factors that can influence your starting wage can in clued the state you live within, whether you came from an apprenticeship program, whether you are good at what you do and how you handle yourself on the job. For many people welding is a lucrative job once they have been on the job for several years. They can also improve their wages by continuing to learn new skills.

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An Overview of Shielded Metal Arc Welding (SMAW)

Tuesday, January 20th, 2009

SMAW welding, otherwise known as stick welding is a process that many welders use because it uses an electrode that is covered. This is called the “stick” and it is one of the least expensive ways to weld.

Stick welding is one of the most popular ways to weld today because it is easy to do and the welder can control it. The stick has flux coated on it so the welder does not have to worry about keeping flux on hand.

How It Works

The way this works is that as the stick is heated, the flux melts. The individual then controls the weld as they work their project and the flux and the stick form a gas and slag that shields the arc that is made. In this way the weld pool stays clear of the molten metal.

The Advantages of Stick Welding

Stick welding is one of the easiest methods to use and the equipment cost is nominal. Because the electrode is already covered with the right amount of flux you do not have to regulate it. You can use this method in any position and it is easier to work with in winds and drafts.

The Disadvantages of Stick Welding

There are a few things that can happen to cause problems if you do not catch them ahead of time. One of the challenges with stick welding is that you can get spatter on your metal. This doesn’t look good and it can be difficult to clean. If you have a metal that has tension or fatigue in it undercutting can be a problem. You may need to start over with your piece you are working.

Sometimes when you are trying to make your weld, your arc can become erratic. This is usually a sign that your electrodes are wet and you will have to get a different stick.

The good news is that these disadvantages can be fixed by paying attention to what you are doing. If you find yourself in a jam and you are not sure what to do, the Internet has a wealth of information on stick welding.

How To Make A Strong Stick Weld

There are many things that you can do to avoid the disadvantages. Make sure that you clean the metals to be welded before you start. Be careful of your buildup so you don’t over do it.

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An Overview of Spot Welding

Sunday, January 18th, 2009

Spot welding is one of the very old processes that people have used for welding. It is done through combining heat with pressure and time. The weld is done through using a current flow through the resistance of the material so that it localized heat in one spot. The amount of time that the current flows into the joint is determined by the thickness and type of material that is being used in the weld.

Another name for spot welding is resistance spot welding and it is one of the few processes that produce small amounts of arc rays and fumes. There are tongs and linkages that are used so an individual must be careful around the equipment for their own safety. Although there are fewer problems it is still wise to wear safety equipment.

The Process of Spot Welding

When a welder is doing spot welding the point is to have the current flow through the very tip of the metals to be joined. The base metal will resist the electrical current which makes the heat focus directly on the join that you want to have welded. The process is unique because you will see that the weld bead is created inside the surface of the base metal. This is different from a TIG or MIG spot weld because the resistance process uses electrodes that are attached to both sides of the work pieces that you want to weld.

Protect Yourself

It is very important to understand some of the safety hazards that can happen with resistance spot welding. As said before the weld is made inside the work pieces so this is not an open-arc process. Here are two common hazards that you should know how to protect yourself from:

You may have flying sparks. You will need to keep a fire extinguisher close and be skilled at using it. Besides causing fires or explosions they can also fly off the weld joint so you need to wear safety goggles and long sleeves. Otherwise you will risk burns to your face and to your body.

Electric shock should be considered. Since you are working with wiring electric shock is always a possibility. To cut down the hazard it is always a good idea to wear insulated gloves.

Keep in mind that spot welding is a very important skill to learn but you must be safe doing it.

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Plasma Cutters and Their Uses

Thursday, January 15th, 2009

Plasma cutters are used in welding when a project requires very high heat. The process started during World War II when there was a need to build aircraft. In order to do this a high heat was needed so they found that by using an electric arc with a protective barrier of inert gas it was able to stop the weld from oxidation.

This was very important because they needed an improvement in the way aircraft materials were joined. As people continued to weld materials they found that if they narrowed the opening that the inert gas passed through, the arc became hotter.

The problem was that this also blew out a channel within the work because the gas flow went faster. Years later the process saw commercial use in the early 1960s. Unfortunately it was very expensive process so they had to use larger burning services to help pay for the expensive plasma cutting equipment.

Today, many manufacturers use plasma cutting because it can burn ferrous and non-ferrous materials. Portable plasma cutters have been created so a welder can literally carry their plasma cutters with them because they are very light. Some manufacturers of plasma cutting machines create a fully mobile unit by also adding air compressors to the equipment.

Reasons to Use Plasma Cutter

Plasma cutters are always used when there is a requirement of high heat for the metal. As an example, you can cut steal easily with it and non-ferrous material that you have to cut quickly. You can cut expanded metal in this and the laser like arc of the plasma cutter is able to be controlled easier than other types of plasma cutters. You can also make different types of cuts so you do not have to stick with a straight line.

Oxyfuel vs. Plasma Cutters

To get a perspective on what plasma cutters can do it is a good idea to compare it with Oxyfuel cutters. What welders have found is that plasma cutting is a much faster and more versatile process than Oxyfuel. It is more versatile because it can cut a variety of metals. Oxyfuel has to stick with metals that can be oxidized because it depends o this process to create what is needed in the process of welding.

Since plasma doesn’t rely on an oxidation process, it can cut aluminum and other metals that Oxyfuel cannot. Usually someone who is new to welding can master plasma cutting faster than they can Oxyfuel or other types of welding.

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Basic Welding Equipment and Welding Safety

Tuesday, January 13th, 2009

Welding is a highly developed skill that most people continue to develop over time. Depending on the type of welding you choose to learn there will be equipment that you need and precautions to keep you safe.

When you decide to learn welding you must understand that there is certain basic equipment you will need, especially for your type of welding. There are some things that every welder will need as they start to learn this trade.

One of the issues you will have to decide when you first decide to learn welding is whether this is something you will do as a hobby or for a living. The welding equipment you will purchase will be different depending on your choice.

Equipment You May Need

There are several practical issues that you need to take into consideration as you purchase your welding equipment. As an example, if you have to have your own equipment for a job or for a hobby you are going to need something to sit your welder and your equipment on. The shop cart is a very good choice to resolve this issue.

You will want to equip it with C-clamps if you need them, wiring and any other equipment that you will want at your finger tips. You will also want a place to put your tools.

Other equipment you might want to consider is a right angle square that will be useful when you want to square up a joint. You will also need an angle grinder that can be used to remove burrs from the metal you are welding, grinding excess bead from the metal or help joints fit better.

Safety Equipment

Welding can be a very dangerous profession or hobby so there is a lot of safety involved. Here is the minimum safety equipment you should have:

  • Safety goggles — to protect your eyes from burns.
  • Auto darkening helmet — this will protect your head from burns and sparks. This will also protect your eyes from the bright light.
  • Particle mask — to protect you from inhaling toxic chemicals.
  • Leather cape — this is protection for your arms and arms and your body and will protect your clothing.
  • Welding gloves — this will protect your hands from the fire and from any sparking.

Once you have acquired the safety equipment it is very important to use it at all times.

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Overview of TIG (Tungsten Inert Gas) Welding

Sunday, January 11th, 2009

TIG welding has had many names and because it started in the 1941s many older welders may refer to it as “heliarc” welding. This welding was initially used in the war efforts to weld airplanes because it did a good job on aluminum, magnesium, and stainless steel.

The reason it was called “heliarc” is because it needed an inert gas as a shielding gas and helium was what was available at that time. As people began to experiment with inert gases they found that Argon was a better choice than helium because it is a heavier gas and had less flow rate than helium.

TIG welding has been found to be a better choice for flat welding because of its even flow. It was also found that TIG welders were able to make a more stable arc and getting the arc going was easier. It is also important to note that the name was changed to TIG but no one actually knows why or when this happened.

TIG Uses Electrodes

The TIG welding process uses a tungsten electrode because it doesn’t burn the way a stick welding process does. Instead the tungsten becomes like a torch and generates the heat which is what actually melts the specific metal or filler metal. If you are welding thin metals you can do it easily with TIG welding. If you need to join thick metals the process becomes more complicated.

TIG welding is a process that has a learning curve and it can be difficult to create a strong TIG weld. Some experts say it is better to learn brazing or acetylene/oxygen welding first because it can teach how to make a good TIG bead. This is very important when you are attempting to learn this skill.

Versatility of the Metals

TIG welding can be used on most metals which make it a very versatile way of welding. Besides the usual metals like stainless steel and aluminum, you can also use it on nickel, copper and titanium.

When you compare TIG welding to other processes like MIG welding you will find it is a slower process. There are also TIG machines that can be used to do this type of welding which has been a welcomed addition to the process. This type of welding is often used in the automobile industry and is used to weld bicycle parts, motorcycles and other vehicles.

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Overview of Metal Inert Gas (MIG) Welding

Thursday, January 8th, 2009

There are many types of welding that are available to learn today and MIG is one of those types. This type of welding dates back to 1940s when it was discovered to weld aluminum and other types of non-ferrous metals.

Many people refer to MIG welding as GMAW or gas metal arc welding. Often these two terms are used interchangeably. This type of welding is considered to be automatic or semi-automatic because it happens quickly. The process works to join two pieces of metal by continuously passing a wire through a welding gun. The wire is connected to a direct current and then passed through the gun with an inert gas like Argon.

The wire acts as an electrode and the inert gas acts as a shield as the welding is performed. This means that contaminates are air borne instead of being put into the weld zone.

An MIG welder will use this method to meld metal quicker than regular stick welding especially when they want to weld soft metals like aluminum. When this method was first started the inert gas was too expensive to do the process all the time. Today, carbon dioxide can be used instead of the more expensive gases and makes this method more cost effective.

Advantages of MIG Welding

There are several advantages of MIG welders:

  • It is faster than traditional methods of welding and it produces longer, continuous welds.
  • It produces a cleaner weld with less splatter.
  • It can be used with a wide variety of alloys and metals which makes it a versatile elder process.

Disadvantages of MIG Welding:

Although this is a very specialized process that works efficiently for many projects there are a few disadvantages that include:

  • The welding equipment is complex and bulky to use.
  • The equipment needs a source of continuous current and a constant feeding of the wire through the gun.
  • It is a very different process than traditional welding so there is a learning curve for all welders who use this technique.
  • Because of the inert gas, MIG welding cannot be used an open area because the wind would cause the gas to cause more problems for the MIG welder.

MIG welding has become very important in many industries because of its ability to weld metals quickly. You will see this type of welding done in many industries that include automobile industry and nuclear industries.

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