Archive for August, 2009

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Plasma Cutter Advantages

Monday, August 31st, 2009
  • It can cuts metals like aluminum, stainless steel etc.
  • Cuts faster
  • Plasma cutting can be done quickly because it does not require pre-heat cycle.
  • Has piercing capabilities
  • Plasma cutting is fast, clean and less expensive.
  • Cuts easily when compared to other process because compressed air is available in various shops.

What to look out for in a Plasma cutter?

When selecting a plasma cutter, portability and performance, ease of use and reliability should be given more importance.

Portability and performance

  • Size and Weight
  • Cutting Capability
  • Duty Cycle Requirements
  • Air Requirement
  • User-Friendly Front Panel
  • Input power
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Things to Look Out for Before Buying Welding Helmet

Friday, August 28th, 2009

Check welding lens while buying welding helmet. Make sure that welding lens protects your eyes from UV and IR rays. Nowadays most of the welding operators prefer auto darkening helmets because they are of high quality and protect your eyes from UV and IR rays even when it is not activated. Always choose a helmet that has darkening time of 4/10ths of a millisecond. Many people are confused as to should they buy solar powered or battery-operated helmet.

A welding operator can choose a helmet based on his personal choice. While buying a battery operated helmet watch out for flash. In this type of helmet, battery will turn off automatically if the helmet is sitting idle. In solar powered helmet you don’t have to worry about changing batteries. Other things to watch out for are it should be lightweight, have sensor bar and helmet is adjustable. A fully adjustable helmet is important for those who wear glasses. Before buying a helmet look out for a manufacturer that offer warranty and replacement parts.

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Guide to Aluminum Welding

Thursday, August 27th, 2009

Aluminum is the most difficult alloy. Initially, aluminum oxide should be cleaned from the surface. Heat treatable aluminum alloys receive their strength from a process called ageing. Notable decrease in tensile strength will happen when welding aluminum due to over-ageing.

Welding aluminum is very easy as it melts easily in low temperature and does not crack after solidifying. Aluminum welding is done according to the type of aluminum used like non-heat treatable alloys containing small amounts of manganese or magnesium and heat treatable alloys containing copper, silicon, zinc or magnesium. These types of aluminum can be welded easily but other metals like copper and lead are difficult to weld and often lead to crack while welding.

Different process of aluminum welding is TIG welding, MIG welding, gas, plasma, resistance welding etc. TIG Welding is best suited for welding pipes and repairing castings. MIG welding is best suited for welding thicker aluminum work pieces at a faster rate and for achieving long, continuous welds. Always clean the aluminum before welding, to remove the oxide layer. Use a stainless steel wire brush used for cleaning aluminum.

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Precautions To Be Taken When Using Portable Power Generator

Wednesday, August 26th, 2009

There was power outage problem in many parts of United States due to snow and ice storms. People should use portable generators with caution when they have power outage problem. Don’t use generators inside the house because it contains poisonous gas like Carbon monoxide that can kill you in a few minutes. You cannot smell or taste carbon monoxide.

Before using Portable power generator, make sure you’re aware of all the safety precautions.

  • Never fuel a running generator because sparks can cause explosion while pouring gasoline.
  • Always keep your portable generators outdoor. Never run the generator in the basement or garage, on the porch, anywhere inside the house. See to it that your generator is away from house.
  • When you’re plugging in your generator, it should be wired properly and there is no water around.
  • Protect your generator from rain, snow, dust if you want to extend its life. If the generator is running in water or wet grass it can lead to electric shock.
  • While buying a Portable generator do get the warranty card for the shop owner.
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How to Choose the Right Generator?

Tuesday, August 25th, 2009

Remember certain points before going out to buy the right generator.

Firstly, find out how much power you will actually need. If you want power for your entire home you have to look in for a generator what many of the hospitals has and that will power your entire house when the electric goes out with a time delay start. Such units may be expensive and require lot of space. You can buy portable generator. Portable generators will not provide power for your entire house but you can get enough power to run your freezer, fans and sump pumps if your power is out for any extended period of time.

The second thing to consider while buying a generator is how large generator do you need. How may watts the generator will be pumping out after starting. Then find out start up watts for each one of your appliances that you will be running on the generator. Then you can find out what size of generator you will need.

Many people find it difficult to find the right generator, but if you remember above two points you can find a great generator for use!

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Benefits of MIG Welding

Monday, August 24th, 2009

MIG Welding is also known as Gas Metal Arc Welding (GMAW). MIG Welding is a commonly used high deposition rate welding process. MIG welding is referred as a semi automatic welding process.

Benefits of MIG Welding:

  • Less skills required
  • Welding cleaning work is less
  • Welding work can be done without stopping
  • Higher deposition rates than SMAW

Primary shielding gasses used are Argon, Argon – 1 to 5% Oxygen, Argon
– 3 to 25% CO2 and Argon/Helium.

Problems face by MIG Welding:

  • Irregular wire feed
  • Burn back
  • Porosity
  • Unstable arc
  • Difficult arc starting

Weld discontinues due to undercutting, incomplete fusion, incomplete joint penetration, Porosity, Weld metal cracks etc.

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Safety Measures for Plasma Arc Cutting

Friday, August 21st, 2009

Cutting Can Cause Fire

  • Keep a fire extinguisher nearby
  • Do not cut on a ceiling, floor, bulkhead or partition it can lead to fire
    on the hidden side.
  • Welding operator and others should protect themselves from flying sparks and hot metal.
  • Do not use plasma cutter to thaw frozen pipes.
  • Do not cut pressurized cylinders, pipes or vessels.

Electric Shock Can Kill

  • While welding always wear dry, insulating gloves and body protection.
  • Do not touch live electrical parts
  • Turn off all equipment when not in use
  • Install an equipment based on owner’s manual
  • Use only that torch which is specified in the Owner’s Manual
  • While welding always use well maintained equipment. Repair or replace damaged parts at once.

Flying Sparks Can Cause Injury

  • Wear body protection clothes so that you can protect your skin
  • Wear safety goggles to protect your eyes
  • Wear ear muffs to prevent sparks from entering ears

Arc Rays Can Burn Eyes and Skin

Noise Can Damage Hearing

  • Use ear muffs if noise level is high
  • Tell people working with you about noise hazard

Fumes and Gases Can Be Hazardous

  • Do not breathe the fumes while working
  • Always ventilate the area
  • If ventilation is less, wear a respirator
  • Always read the Material Safety Data Sheets (MSDSs) for
    metals to be cut, coatings and cleaners.

Plasma Arc Can Cause Injury

  • Keep away from the torch tip
  • Pilot arc can cause burns
  • Do not grip material near the cutting path
  • Use only torches that are specified in the Owner’s Manual

Cylinders Can Explode if Damaged

  • Keep cylinders away from electrical circuits.
  • Use the right equipment, correct procedures and sufficient
    number of persons to lift and move cylinders.
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Process of Brazing

Thursday, August 20th, 2009

Brazing joins two pieces of base metal when melted metallic filler flows across the joint and cools to form a solid bond. The two base metals like silver and bronze are perfect for brazing. The process of both Brazing and soldering is same, but the only difference is that metals and temperatures differ. Brazing handles more unusual configurations with linear joints.

Before starting braze work it is important that you clean the entire area properly and then apply melted flux. Flux can remove oxides, prevent oxidation during brazing and smoothes the surface so that braze “flows” evenly across the joint. Then you gather the torch and braze alloy. Finally, you complete the joint by applying braze. One major advantage of Brazing is a brazed joint is smooth and complete, creating an airtight and watertight bond for piping that can be easily plated so the seam disappears.

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What Are Welding Machines?

Wednesday, August 19th, 2009

In simple terms, Welding refers to fabrication process that joins materials such as metals and thermoplastics. For welding different processes and energy sources are required like gas flame, electric arc, laser, electric beam, friction and ultra sound. Welding machines are classified into different categories based on welding process and equipment used during process. Some welding machines require transformers to convert high voltage, low current electricity into high current low voltage. This type of welding machine is least expensive.

Inverter based welding machines use high-power semiconductors like IGBT for handling high loads of arc welding. These machines convert electricity into high voltage and store them in a capacitor bank. The stored energy is transferred to secondary transformer for producing desired welding current.

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Points to Remember for Metal Inert Gas (M.I.G)

Tuesday, August 18th, 2009
  • M.I.G is also known by manufacturer’s trade name as Micro-wire, Sigma and Miller matic Welding.
  • MIG Welding is faster to learn
  • It can weld faster than stick electrode welding.
  • While welding steel, carbon dioxide acts as a shielding gas which is less expensive and most effective.
  • For MIG welding, wire stick out should be 3/8” to ¾”.
  • If a welding operator uses Argon gas and oxygen for welding
    aluminum     and stainless steel it will provide best results.
  • Gas flow rate for welding most metals is approximately 35 cu ft/hr. But this can changed based on the type, electrode size and thickness of metal.
  • It is important to use correct diameter wire electrode for quality welds.
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