Tig Welding Troubles With Aluminum


March 2nd, 2010

The total number of times the AC TIG arc changes in between the electrode negative and electrode positive in one second is known as Frequency or Hz. Take in consideration the Miller’s Dynasty 300 DX inverter-based TIG power source, it always allows to alter the frequency of the power supply from 20 to 250 Hz.

It’s notable that usual TIG machineries have a fixed amount of frequency which is something to that of a 60 Hz of primary power. When the frequency of the power sources is increased, you can find that it trims the shape of the arc cone and boosts up the arc force. Because of this the arc is reduced and stabilized, moreover gives exceptional directional direct on the arc.

On lap and T-joints, by a high frequency gives ways to set up the weld puddle right at the root. Resultantly, we get a good infiltration and moreover the etch zone is also minimized.

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Mig Welding In A Nutshell


March 1st, 2010

MIG Welding is one among the simplest methods for any learner to become skilled at. It is normally that many freshers learn to do a lot of thing in a short time with MIG welders in just a few hours of time. Learners can keep it simple and learn the process to do great things easily. Apart from learning to run beads, there are actually a lot of things to learn about in the fundamentals of welding techniques.

Has anyone though about the time when MIG was used first? MIG came into being at the time of World War II. It was expanded and built further to assist manufacture of weapons and other gear needed for the war even quicker. MIG Welders were then used in the post-war for booming economy, more often than in stores and manufacturing industries.

MIG means metal inert gas. The flux on the electrode melts and gives a gas to guard the weld pool formed from the air in Stick Welding. We know that the hydrogen, nitrogen, oxygen, and other gases are present in the air and this will lead to weld defects if it is permitted to get into the weld pool. A reel existent of solid steel wire is given inside the apparatus, through a lining, then out of a contact tip in the gun.

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An overview of CNC plasma cutting


February 25th, 2010

The CNC (Computer Numerical Control) plasma cutting has been prevailing since many years. But due to the high costs of machinery, it was not affordable to the small industries. Recently it has become affordable enough for all industries.

Generally, the plasma cutting process is known for its surgical precision. In the manual plasma cutters, the plasma cutting torch is being handled by humans. As a result, a kind of roughness is sometimes found in the plasma cut pieces. With the advent of CNC plasma cutting, the process has been more precise. In the CNC plasma cutting systems, the operator’s personal computer is been used to control the cutting torches and also creates the shapes to be cut. This process enables to cut intricate curves, inside cuts and sharp edges with a smooth precision that is usually possible only with hand saw. The computer is capable of controlling the movement of the plasma cutting torch as it turns it slightly before the process so that it would burn through the material first.

With the advent of technology, the CNC plasma cutting equipment has become capable of multi-axis cutting of thick material. This enables complex welding which is not possible in other plasma cutting systems. However, for cutting extremely thinner material, laser cutting with superior hole-cutting abilities has been used. The HVAC industry had also been utilizing CNC plasma cutters where the software would process information and creates patterns which have to be cut by plasma cutting torch. The technology has enhanced the HVAC industry since its introduction.

The CNC plasma cutting machines have undergone many developments in recent years. Horizontal cutting tables were used in the machines earlier but with further research and development, vertical CNC plasma cutting machines were introduced. The advantages of these machines include small foot print, flexibility, more safety, fast process, maximum utilization of energy and moreover eco friendliness.

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How MIG welders differ from Flux Core welders


February 24th, 2010

When you are about to purchase a wire feeder welder, you must primarily keep three things in mind. To begin with, you must see what you are planning to weld and secondly where you are welding. Finally you must check the surface finish of what you are welding. You must also select the appropriate welding method that would go with the type of metal you are welding.

You can begin your welding lessons with the Gas Metal Arc Welding popularly known as the MIG welding which uses a solid wire electrode for filler metal and an externally supplied gas from a high-pressure cylinder for shielding. It is used for welding commercial metals like low carbon steel, low alloy steel and stainless steel.

Once you get comfortable with steel welding, you can try your chances with aluminum welding equipments. Since aluminum is a very soft metal, cleanliness of the wire and base metal is important. Special welding techniques are often required to weld aluminum. On the other hand, the Flux Cored Arc Welding or the Flux core welder is different as it uses internal shielding gas and fluxing agents through a wire which has the needed materials in its core and produces them when heated.

While comparing the MIG welders and Flux core welders both has advantages and disadvantages. The MIG welders provides lower spatter levels compared to the flux core. But they don’t offer portability. The flux core welders are best suited got outdoor welding but the machines are highly sophisticated and a slight change can create a big difference. MIG welding is easy to learn while flux core is hard to master. The MIG welding has a soft arc which is not suitable for welding thicker materials. The flux core process is best suited for welding thicker materials as it is devoid of cold lapping.

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Things to know before buying a plasma cutter


February 23rd, 2010

Plasma cutters are available in different shapes and sizes and it is really confusing to select a perfect model. Before buying the plasma cutter you must have a clear idea about its usage and your needs.

Generally plasma cutters cut anything including aluminum, copper, stainless steel and other steels. For determining the thickness of the piece you are cutting, you must know the type of the metal being used. For cutting a quarter inch metal, you would need a plasma cutter that would cut cleanly, quickly and efficiently. Once you know about the type and thickness of the metal, you must decide upon the speed in which the cutting should be done. A bigger machine is required for faster cutting of metal. Here you have to consult an expert before going for a big machine since the machine would be tough to handle.

A high power plasma cutting equipment would require high voltage. So if you are buying a high power cutter, you should enquire about the voltage required and also about the availability of such high voltage in the work environment. If you are opting for a portable plasma cutter, then size and weight should be the prime concern. Plasma cutters which can be put inside a box in your truck to be carried to the work site are available in the market.

Plasma cutters are commonly operated using inert gas (often compressed air). Before buying the compressed air, you must know the Cubic foot per minute i.e. CFM of the compressor and it has to be at correct levels for the accurate operating of plasma cutters. Information on the proper gas supply could be sought by knowing the pounds per square inch (PSI) that the plasma cutter requires to run.

The most important thing before operating a cutter is that you must strictly follow the plasma cutter safety guidelines. Operating a plasma cutter is very much different than regular welding. So it would be better to take all the needed precautions.

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Welder’s have to follow Safety Measures


February 22nd, 2010

Welding is the best option of joining any same or different type of metals. In every industry or welding industry welders perform their job in welding the metals and give the finishing touch to the welded materials. The welding process takes place even at household environment.

By following various welding types and techniques welders perform their role to weld out any sort of metal. The job of welding is not so easy if it is not followed by various safety measures. It involves lot of risk and any mismatch in any of equipments or source will cause serious injuries or harm to them self and to others or sometimes it leads to the death.

A person who is involved in job of welding should be well trained and expert in welding techniques. If he is expert in one welding technique or process then he should stick on that and if interested can learn the other techniques under the supervision of expertise who is already expert in that following methodology of weld.

The work of welding can be carried at any place and there is no possibility of predicting any work place as the best and protective one. Therefore it becomes necessary for the welder to do his job by protecting himself wearing required jacket, gloves, caps, goggles, clothes, shoes, and handling of the welding equipments depending on the need of the particular weld process.

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A Guide on Friction Welding


February 19th, 2010

In Friction welding the method apply for welding process is to rub one object with another to fuse them together. As fusion take place when pressure is applied on both the objects. Since heat is generated from the friction of two objects there is a minimal level of effect to the surrounding areas.

Friction welding process is suitable for the objects where the melting points differ. As the process is only for fusion of objects melting is not done during the process. As the method is like forging of the objects. During the friction of objects two types of welding takes place. In the first stage two different metals are fused together and in the second stage thermoplastics are used.

When the objects are fused together spin welding technique is been used. In this technique it rotates one piece of the metal while other piece remains ideal. When pressure is applied rotating piece is stopped. The other similar method for welding that can be used is linear welding. The only difference between the two process is in linear pieces are rubbed in up and down direction where as in spin it rotates. Plastics and metals can be joined together with the help of thermoplastic process. It is advance way to join the metals which are not possible in traditional welding process.

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MIG Welding and its Types


February 18th, 2010

Metal Inert Gas in short term known as MIG welding. It is popularly known as Gas Metal Arc Welding. In Mig welding process the usage of aluminum alloy wire with the combination of filler material and electrode are used by the welders. The process is one of the easiest processes that one can learn to weld. As the welder is capable of meeting all the parameters of welds with the help of machine it can also be termed as semi-automatic weld.

Mig welding can be carried on at two different processes they are:

  • Conventional Metal Inert Gas weld-
    In this process of welding it uses DC power source with constant voltage. As there is limitations for the spray transfer, for the arc current the welding has its lower limits. Since it is limited to certain range it can weld materials where the thickness being above 4 mm.
  • Pulsed Metal Inert Gas weld-
    Here the passage of DC power source is retained at low and high intervals. When the welds are done at low current welders maintain the arc without transferring metals. And during the high current passage metals are transferred in spray mode. Therefore this makes Pulsed welding process to weld at high and low heat inputs which is not possible in conventional process. And the possibility of welding thinner materials is much easier at any positions.
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Overview of Electroslag Welding


February 17th, 2010

Electroslag Welding (ESW) the process of welding is to join two plates or metals by depositing the weld metal in the weld cavity. In order to prevent the running off of molten slag the space is covered with the help water cooled copper dams. Since the depositions rates are very high in Electroslag Welding it is considered most productive welding techniques for joining very thick metals. The process makes the use of direct current to weld the thicker metals and so the need of making an arc is extinguished.

Advantages of Electroslag Welding method include:

  • Highly productive in welding techniques
  • The cost of making a joint is very low
  • The welding process can be carried on a single pass without taking into the consideration the thickness of metals
  • During the butt joints there is no angular deformation
  • The stress of transverse is very little
  • The risk of hydrogen getting cracked is low
  • Major repairs can be done in simple techniques by cutting out the weld totally and re - welding it
  • The speed of welding joints is 1 hour/ meter of seam, where the thickness of material is not taken into consideration
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Overview of Electrogas Welding


February 16th, 2010

Electrogas welding in short termed as EGW. It is an advance technique of electroslag welding where in it gives much better designs and usage is easier. In Electrogas welding, electrodes are been meted instead of slag. Electrodes which are melted by forming an arc with the help of shielding gas, the process is same as the MIG/MAG welding.

Electrogas welding enables the flow of electrodes and work pieces into the cavity of metals which are welded. This welding can be carried on for the weaving of thicker metals around 12-100m. The joint which is formed here is a simple I-joint in where the gap is formed. Welders can also weld in V-joints. If the welder makes use of long electrode stick the speed of welding will be higher and the molten produced in base material will be less and the temperature also becomes lesser.

EGW can be helpful in welding steels and some stainless steel. The visibility of welding is much more visible to the welders. Welders have to be careful with the weld procedure as large amount of molten is present during the welding. Operators should put on all the necessary welding attires with additional safety and fire hazard. A constant voltage of around 30-50 V and power supply been around 100 -800 A is essential.

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