Archive for December, 2010

What’s the use of welding?

Friday, December 31st, 2010

Modern welding procedure is engaged in the construction of several products. Ships, buildings, bridges, and entertaining rides are engineered through the process of welding.

Welding is often used for fabricating the machines that are further used for manufacturing/developing newer products. Such technique of joining metals/alloy materials has made it possible for airplane manufactures to meet the design demands strength to weight ratios for both commercial and military aircrafts.

The exploration of space would have not been possible without the aid of modern welding techniques. From the commencement of early rockets to today’s aerospace industry welding has played its major role(s).

On an average each day a new method of weld is thought out and new styles are also thought out so as to make the process of weld easier and user-friendly. Many of such improvements have improved our lives and have made our lives easier too.

The idea of weld is extensively used in the fabrication of automobiles, farm gauges, home appliance, computer components, mining equipment and earth moving machineries. It is also used for fabricating railway equipments, furnaces, air conditioners and thousands of other products that we use in our day to day lives are joined together by some type of welding techniques and methods.

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A Guide Towards Magnetic Rotating Arc Welding

Thursday, December 30th, 2010

Magnetic rotating arc welding is also named as magnet arc welding or magnetically impelled arc butt (MIAB) welding that is developed in 1970’s. It is an arc fusing method where an arc is made between the punched ends of pipes and pushes around the fuse bond by a magnetic field, trailed by an upsetting operation. In general, the process is a combination of forge and arc welding with a gas protecting operation added on.

When the arc is created, a magnetic wind around the joint resists the arch that drives it around the boundary of the piece. The arch dashes around the piece at a rate near to 50 meters per second. In this pace the bend appears as like it is a ring of light amid of the pieces.

Once the arch has dashes around the piece for the particular period of time, the two parts are pushed together to weld them. This procedure is becoming very popular, when it comes to mass production environment. The whole method is fast, can be mechanized and needs comparatively little power than other kinds of welding. The pieces don’t have to be cylindrical.

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Methods Utilized To Perform The Weld

Wednesday, December 29th, 2010

The welding engineer or a welder must not only settle on the process of welding but they must also decide on a method for its effective application. Following methods are utilized to perform the task of welding, cutting and brazing operation:

Manual welding: welder is obliged to manipulate the entire process of weld.

Semi automatic: filler metals are added automatically and all other operation is completed manually by the welder.

Machine: here the process of welding is done mechanically under the surveillance and correction of a welding operator.

Automatic: here the process of weld is performed repeatedly by a machine that has been programmed to do the complete operation of weld without having any interaction with the operator.

Automated: operations are executed repeatedly by a robot or by other machine that is programmed gymnastically to do a range of processes.

At earlier days, emergence or usage of machines was not much into the picture. But as of now many weld operations are performed with the help of required machineries.

Today for each weld technique various torches and guns are made available so as to get the desire results on weld metal. There are some weld techniques which still asks for manual application so as to give out desired results.

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A General View about Electroslag Welding Process

Tuesday, December 28th, 2010

Electroslag welding or so called ESW is a process in which a main arch is utilized initially to heat up the slag and then repressed by the conductive slag. This procedure is typically used to join steel in a vertical position. Even though Electroslag is not an arch welding process but an arc is temporarily lighted in the starting stages. Before this, there is no arc ignited in it and the width perimeter for this method used to be 30″. Excessive heat facilitates to get this kind of access, and various electrodes can be utilized to expedite the procedure.

Electroslag welding became a famous choice in the 1970′s, intended for fusing metals that were especially thick that comprise parts for building, bridges, ships, and heavy vessels. This process can join very thick metals and many electrodes can be utilized to finish a bond in a single overtake. Generally, the high temperature is detained in the joint for long time and gas froths are set aside to flee from the bond pool sooner than it cools. The whole procedure is mechanical and if starts once, it doesn’t end until the bond is done.

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Types of Automated Welding Process

Monday, December 27th, 2010

“Automated welding” as the name says is done automatically or by machine. This process is divided into two categories:

A) Fully automated welding process
B) Semi automated process

Both the processes are same up to certain extent as they have automatic mechanical component that allows them to fuse a piece of metal. These procedures are computer oriented that provide them their controls over operations, this mechanism usually called their controller units.

However, there are some differences between them such as; when it comes to fully automated welding process, it needs minimum human interface to perform its functions. On the other hand, if it is the semi automated welding process then it requires great amount of human involvement to get the welding job done with accuracy. Fully automated process can fuse at high speed that is not possible manually. These machines have the capacity to repeat the procedure at very fast velocity and their repeatability over & over again provides them supremacy.

Semi automated welding procedure is reliant on individual interface. This operation requires the operator to do quality inspections or check for error if any. This process must have a welder to carry out the task.

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Usage Of Computers In Welding Industry

Friday, December 24th, 2010

Likewise in every skilled trade, in today’s fast changing world, the usage of computer is becoming more common in welding industry too. A few of its basic program structures offers a cross reference to welding filler metals, other programs support in selection of weld symbols.

Some of the multifaceted program structures permit welders to design structures and at the same time experiment them for its durability without ever constructing them. Such computer programs assist in generating proper and accurate designs and make more efficient usage of materials which further results in better and more lucrative construction.

Universally used programs are Arc Works is made use for documenting Welding Procedure Specifications (WPS), Procedure Qualification Records (PQR) and Welder Qualification Test Records (WQTR). These documents are broadly employed all over the welding industry.

In general most welding programs function in array of platforms, but the most accepted ones utilize the version of Microsoft windows. Those welders who understand the working of Windows will witness a good start with the programs and software’s that are designed for welding industry. Through this the job of weld becomes easier and they get an opportunity to work effectively.

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Take Care of Burns That Might Occur During Welding:

Thursday, December 23rd, 2010

Safety is very important that has to be considered at the time of welding. Whether it is a MIG, TIG, Stick, or any other technique of welding a welder must make sure to perform the weld with appropriate safety equipments and with suitable welding tools.

During the process of weld a welder may get injured in many ways. One of the most common injuries which every welder would have experienced is “burns”.

Burns are one of the most general and hazardous injuries that occur in the welding shop. Burns might occur through ultraviolet rays and if contacted with hot welding materials. The possibilities of getting infected are very high due to the dead tissue. Hence it is very important for a welder to get an appropriate medical treatment for the burn so as to reduce the chance of high infections.

In welding industry burns are divided into three classifications depending on the degree of the severity. They are

• First degree burns- skin in reddish color, tender and painful but it doesn’t involve any broken skin.

• Second degree burns- skin will be severely damaged which in turn results in formation of blisters and a possible break down in the skin.

• Third degree burns- surface of the skin and possibly the tissue below the skin below appears white or as charred. Since nerve endings get destroyed over here there would be no feeling in that particular area.

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Spot Welding- A Unique Welding Process:

Wednesday, December 22nd, 2010

Spot welding is one of the very unique techniques of welding that people have used. This welding is performed by combining heat with pressure and time. Further to this, the process is carried on by using a current flow through the confrontation of the material so that it localizes heat in one spot. The amount of time taken by the current to flow into the joints is based on the thickness and the type of metal that is going to be welded. The main advantage of this type of welding is that the entire sheet does not get heated up during the process as it takes very few milliseconds for lot of energy to flow to the spot to be welded.

Spot welding is also known as resistance spot welding as it is one of the few welding procedure which generates fewer amounts of arc rays and fumes. As tongs and linkages are used, welders have to protect themselves for their own safety from the equipments that are kept around. Hence it is advisable to wear safety equipment before performing the welding activity.

When a welder performs spot welding he has to make sure that the current is flowing through the tip of the metals which are going to be joined. This process of welding is unique as you observe that the welded bead is formed inside the surface of base metal. This process of welding is different from a TIG or MIG spot welding.

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Shielded Metal Arc Welding (SMAW) Is A Flexible Welding Process:

Tuesday, December 21st, 2010

Shielded metal arc welding (SMAW) is one of the most widely used welding processes among welders due to its low cost, flexibility, portability and usefulness. Machines and electrodes that are used over here are of low cost. The device itself can be as simple as a 110-volt, step down transformer. Electrodes are available from a large number of manufactures in various sizes of packages.

The SMAW procedure is a very flexible kind of welding process. In this process you get a chance to weld metal of any thickness and additionally you can also weld them in various positions.

Shielded metal arc welding process is a very portable kind of process for the reason that it is very easier to move the equipments. In this kind of weld, engine-driven generator type welders are also available. Moreover the limited amount of equipment that is required for the process makes moving process easier.

Shielded metal arc welding is ingenious and it can be used for welding almost any kind of metal or alloy, including cast irons, aluminium, stainless steel and nickel. The flexibility of the process allows metal of any thickness to be welded in any position.

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Power supply essential for Arc Welding:

Monday, December 20th, 2010

Arc welding is one among the universally known procedures. It has got the name as “Arc Welding” because of the electrical arch that is created once the welding process is completed. The arc is the result of high temperature to the electrodes and the +ve & -ve charges that are produced from the heat. All ions are excited in a whirl at hasty pace that facilitates to produce the electrical arc or the beam, which often comes from the torch.

Now let us see how it is the best power source. This is the core of every arc welding process because it’s the welding power supply source. In general, the power source has the alternating current (AC) that will rotate in its direction. Consequently the alternating current will move forward with its energy after that it reverses and maintains this irregular system right through the entire work.

On the other hand when it has direct current or DC, supply will persist to flow frontward and continue in the similar way until the work is done. The entire process is relied on the kind of electrodes you employ and the nature of supply material used.

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