Posts Tagged ‘Arc Welder’

Plasma arc cutting and its insights

Monday, April 30th, 2012

Plasma arc cutting is a thermal material elimination process that is principally used for cutting thick sections of electrically conducive materials furthermore it can be defined as a “superheated, electrically ionized gas.”

To put it in simple and comprehensive terms, it is an arc cutting process that cuts the metal by melting a localized area with a contracted electric arc which removes the molten material with a high speed jet of hot ionized gas concerning from the contracting orifice.

This process requires plasma cutting power source along with

  • Torch
  • Electricity
  • compressed air

Designs can be cut by a free hand, by tracing a representation, or by following an outline. With the help of computer controlled system, intricate and repetitive patterns can be cut effectively. The process is very simple, the metal to be cut is lay out, plasma machine and the compressed air is turned on and the torch is placed on the metal relying on the torch configuration then the trigger is activated hence the metal gets cut through this hierarchical process.

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Tips to select the perfect welding helmet for your welding requirements

Friday, April 27th, 2012

Welding as we know it is a process wherein two or more metal pieces are joined together with the help of a molten solution that forms the bond between them upon cooling and solidification. Theoretically speaking, it is as simple as that. Practically speaking, Practice makes a man perfect and in order to understand and imply the intricacies of this art, one needs to apply tremendous amount of focus, knowledge and concentration time in and again. Every professional welder knows about this pretty well.

Practically speaking, welding is also one among the dangerous tasks we could ever undertake. A simple mistake is more than enough to spoil the weld on a lighter version. On a broader version, such a mistake could severely injure you, blinding you or even cause death under worst case scenario. One ought practice caution by all means and not be fools hardy.

Irrespective of whether we are performing welding with a MIG welder or a TIG welder, the welding helmet is the pivotal point of our requirements. One mustn’t forget that at any cost. As far as safety aspects go, everything is equally important while performing welding. However, one must be able to choose the perfect quality welding helmet that could last for several years and serve to be as resourceful as possible.

There are 3 parameters that you need to consider while shopping for these helmets. They are:

  • Health and Safety
  • Productivity
  • Quality.

A welding helmet that you choose must provide sufficient protection for the eyes, face and neck. Protect your skin from harmful UV rays. It should provide protection against sparks or splatter, infrared light and many more. A proper helmet will be comfortable and help you to focus which significantly improves productivity. If you are feeling heavy or fatigue during welding, your productivity will be hampered. Hence, purchase a helmet that keeps you comfortable and protects you efficiently. Quality helmets as expected serve to be resourceful for several years to come.

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Metal cutting done best through plasma cutters

Wednesday, April 25th, 2012

Plasma cutting machines are of great use for any industrial applications. They are an effective metal-cutting tool with new technology that will help you meet that laser accuracy. In turn, it’s this laser accuracy that makes the plasma cutter a great cutting machine.

To put it simple, plasma cutters are familiar metal working instruments that are competent of cutting through different types of metal in a single slide. Moreover, they are to be had in different types of thickness cutting options as well. These cutters have the outward show and competence of a wire-feed welder. They are most commonly used in heavy fabrication industry, for the plasma flame have that very powerful and energized stream of ionized gas, that’s also holds on to the limiting part for the precision process.

In fact, Plasma cutting was primarily formed to cut metals without the existence of iron in them. These days, it can be completed on metals with and without the presence of iron. Besides, the cutting of different metals, it can also be used for accuracy piece work and serving shape unlike metals. The plasma cutter can spot curve lines on dissimilar metals so an additional machine can execute the bend or curve.

With the advent in technology, there were several alterations done in the plasma cutting systems. These cutters do not cut through metal using a flame as an oxy acetylene torch does; but make use of high voltage charge to ionize a high velocity stream of inert gas which alters into plasma when it attains a high temperature. As a result, it cuts through the metal by melting it with little impact on the adjoining metal and is very clear cut because of this phase.

This level of precision is achieved only in the recent years. Comparatively to the earlier days, these cutters were less precise and it was of a blunt device. As technology progressed the change in the industrial tools gave progress to superior and precision based work. The recent technology has permitted the expansion of a lesser yet focused flame to give a more perfect and tidy cut while using lower power. The best part is these cutters have an inbuilt air compressor and are designed for a small workshop with adequate flexibility to take on a range of tasks.

Plasma cutter buying guide:

The utmost imperative factor that you should consider is the thickness of the metal that you are going to cut. In general, these cutters are rated by their competence in cutting and amperage. In case if you are planning to cut a metal that is considerably less in thickness then consider getting low amperage plasma cutter which will help you cut it best. On the whole, the optimal cutting speed of the device should be cropped down before you get one.

Make few test cuts before you buy one to check the cutting consistency along with the precision of it. To make it right make sure that you follow these steps for that precision cuts.

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Driving force for plasma cutter

Monday, April 23rd, 2012

Heavy metals and alloys forms the building blocks of each one of the tool in the modern industry. The strength and durability of metals are the reasons behind its extensive usage of for various industrial purposes. When it comes to designing and modification of metal structure, the strength of the material would become the weakness of the same. For such operations, the plasma cutter is implemented. This method has been under existence since Second World War.

A flow of plasma is generated here with the use of plasma torch or plasma arc so as to enable plasma cutting. Inert gas gets blown through a nozzle at a very fast rate and an electric arc is formed along with this gas flow. This happens over the surface of the metal or steel which is about to be cut. The plasma will be so hot such that the hotness is sufficient enough to make a cut over the metal and blow away the molten metal.

The concept behind the functioning of plasma cutter is that, when the gas is subjected to extremely high temperatures, plasma is obtained. With high temperature, the molecules get split into atoms and the electrons in these atoms would become free to move in and around, leaving out the atoms only with positive charges thereby making them ions. The collision of these electrons with the other ions would release enormous amount of energy which is wholly responsible for the functioning of plasma cutter and it acts as the driving force to make the cut.

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Safety measures during Mig welding process

Friday, April 20th, 2012

The term mig welding stands for Metal Inter Gas welding. This type of metal welding process is widely handled in most of the industries. It is carried out by the application of heat obtained from the electric arc over the metal work piece. Certain safety measures have to be implemented well before we start working with these welding procedures. Firstly, protection of skin from harmful ultraviolet radiations is to be considered.

Appropriate ventilation facility, usage of extraction fans and wearing a vapor mask are few of the protection methods for avoiding the effects of UV rays. Sparks will be released at the time of grinding and welding operation. These sparks can travel a very long distance and hence care should be taken such that sparks does not affect any object by catching fire. Avoiding the placement of flammable objects nearby areas of such operations is the best way to prevent fire accidents.

Cornea of human eye is so sensitive to rays such as Ultraviolet radiation and sun burns. Even if the arc is seen for a very short period of time, it will affect the cornea very easily and this condition is termed as “Arc eye”. It is highly dangerous and a proper protection to the eye is to be given before mig welding process is started. Protecting the workplace with the help of screen will help out if there can be any passer-by in and around the area of welding.

Vapors and fumes should be cared properly and we need to make enough safety measures for mig welding with Zinc and Aluminum objects. Sawdust or other tiny paper bags could catch fire easily at a very fast rate and hence special attention should be shown on them so that we do not miss any such tiny object. The conventional methods of having a fire extinguisher aside or a bucket full of sand are the two all time best ideas for any kind of welding work.

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Is it imperative to be a certified welder?

Wednesday, April 18th, 2012

Welding as such is an art that can be perfected only through practice and experience. There are no short cuts to become a professional welder and every welder started in your shoes. Theoretically speaking welding as such is quite simple wherein two or more metal pieces are joined together with the help of a molten solution that forms the bond between them upon cooling and solidification. It is as simple as that and there are no big secrets or special techniques hidden inside when it comes to understanding welding.

However, practically speaking, it is one among the most complicated tasks one could ever undertake and welding should never be taken lightly. It requires immense focus and precision in order to create sturdy welds. And a professional welder is identified by his qualifications. He needs to be certified by the proper authoritative boards in order to legally practice as a professional welder. Is it imperative for you to become a certified welder? Certainly yes and you don’t even have to think twice about it. And once you become a certified professional, you become a comprehensive who could perform any kind of welding procedures with any kind of welder including MIG welder, TIG welder, Arc welder, Stick welder and many more.

And becoming a certified professional welder is not all that difficult.

  • Call an AWS accredited center and arrange for a simple welding test.
  • Pay some entrance exam amount which is very nominal.
  • Practice harder.
  • By performing a simple T joint weld is more than sufficient for you to pass the certification. Of course, all I’s should be dotted and T’s should be crossed.
  • Then with a small amount you can be registered as a professional and certified welder of National AWS Certified Welder Registry.
  • You are most likely to get a welding job immediately once you are certified.
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Imperative 7 welding safety tips that ought to be followed

Tuesday, April 17th, 2012

The below mentioned welding safety tips are highly mandatory and should never be neglected while performing any welding activity for that matter. Welding is one among the simplest concepts theoretically speaking and yet it is also one among the most dangerous activities one could ever pursue. There are only 10 major mistakes you could ever make that could turn out to be quite fatal. And yet welders treat these as mere instructions manual and don’t give too much about it unless there is a real problem. Such shouldn’t be the attitude at any cost. The problem could prove to be quite fatal and even life threatening. You might not be around to correct the mistake only.

  1. Oxygen and Acetylene cylinders serve to be very useful while welding and there is no doubt about that. But a little leak of gas is more than enough to cause an explosion killing you instantaneously. So be careful while transporting them.
  2. High pressure cylinders need protective caps. Without such caps, when the cylinder falls, its knocks the valve and boom, you only have fraction of seconds to live.
  3. See to that you are clean and does not carry any flammable substance in your pockets before welding. A cigarette lighter is more than enough to cause an explosion while welding if you forget its presence.
  4. Making use of MIG welder or TIG welder inside a tank. Both use Argon shielding gas and argon as a gas is heavier than air. It can fill the tank quite easily and without sufficient ventilation, you won’t have oxygen subsequently leading to your own death.
  5. Never weld with water around. Water supports low voltage and high amperage levels which can cause instantaneous shock and death consequently.
  6. Welding is a skill which ought to be practiced with at most caution. Be careful with flammable items around you while welding. Be watchful of flammable products around you at all times.
  7. Welding a tank that carried flammable products in the recent past. You have to be highly careful in such situations. Special precautions ought to be undertaken.
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Getting Started – Need to know – Starting off MIG welding?

Monday, April 2nd, 2012

Gathering information on what you will need? Look no further. Over the next few blogs, we are going to be dealing with the elementary aspects of MIG welding. These are the things you need to know to make an informed purchase, or to get you started. One of the first areas you absolutely must know is the difference between true MIG welding and Flux core welding. As the MIG welding market has grown, it has been common to refer to any style of semi automatic welding with a spool of wire, and a gun to feed it with as MIG. This is not correct. Officially, the term used to be called MIG or “Metal Inert Gas”. The gas is used to shield the molten weld pool until the metal has solidified to protect it against oxidation, and porosity that is introduced from the atmosphere. Nowadays it is referred to more specifically as GMAW or “Gas Metal Arc Welding”. Note that both former and latter terms use the word “Gas”. In fact, there is no such a thing as gasless MIG welding. Anytime Gas is removed from the equation, you must deal with the terms cored wire, or more accurately Flux core welding. The look of the welder may be the same, but the wire is where the difference is. Internally, within the wire, is a soft core of flux, which substitutes for the shielding gas used in MIG. Officially these days it is referred to as F-CAW or “Flux Core Arc Welding”. It performs the same operation, by sheltering the molten weld pool from the atmosphere as it cools to prevent oxidation and contamination without the gas used in true MIG. There is a form of welding that is called dual shield which allows both shielding gas and flux filled core wire to be used. This is in high end commercial applications for specialty welding, and is not something that you’d likely consider at the outset. Commonly all forms can be referred to as wire welding, and the units as wire feeders. But it is important to know which is what and how and in what situation each process is favored and used.

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Plasma Cutting – Watch the Dross

Friday, March 30th, 2012

On the underside of any plasma cut, small amounts of slag may collect along the sides of the cut. This dross can be significant or minimal. It can be hard to remove, or easy to remove. If it is significant, and hard to remove, and you notice that the cut line angle dramatically increases toward the rear of the weld, it is a good sign that the maximum cut capacity of the plasma cutter is near or the maximum cut for the set amperage has been achieved. If it is significant and hard to remove, but cut lines are normal, air pressure may be low. If the dross is significant and hard to remove, and the cut lines are irregular, then cut speed may be too fast. If dross is irregular, then cut speed may be varying, or torch height may be changing. If needed use a cut guide, or a standoff to keep a consistent cut height. Be careful also to watch for discoloring of the cut or sootiness, of the consumable, if any negative cut condition occurs. This may be an indication of moisture in the lines. Ideally, the cut should have less than 1/8” of dross on the cut backside, and cut lines are angled at a 30-40 degree angle toward the rear of the cut if all things are working as they should. Melting back over of the dross or closing up of the cut can indicate too slow of movement, or too low of air pressure or too high of amperage for the thickness. Loss of cut can indicate too fast of travel speeds as well.

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Improving technique and consumable life – Plasma Cutting part2

Wednesday, March 28th, 2012

As much of a factor as the pilot arc duty time is in determining overall consumable life, proper torch manipulation is just as important, for both consumable life, and cleanliness of the cut. As already mentioned, having the torch close to the metal, ready to cut when the torch trigger is pulled is important. But also important, is starting the cut at or near the edge of a piece of metal when possible. If a part is drawn out or a template is used, the part to be cut should be placed on the metal to with at least one side near the edge or corner of the material. This will allow the torch arc to start just off the side of the metal, and the torch to be moved quickly into the full cut. This will allow a short “lead in” for the cut, so that little metal is wasted, and starts can be started, without the flame needing to cut through the entire length of metal first before starting the cut. Starting the torch in the middle of an intricate design, or cutting a hole in an object, will require a technique known as piercing. Piercing involves a steady hand and some for thought. Vertical piercing, where the torch is held 90 degrees over the cut, is the quickest way to destroying consumables and even the torch, especially on thick materials. CNC use cutters do in fact use this technique, but in reality, the capacity of a plasma cutter when used with a CNC table is cut in half because of this. Blowback from the spark and flame when the cut is started from straight overhead is redirected right back into the face of the consumable and torch. This blowback sends hot sparks, flame and material the wrong direction! For best use when piercing, identify the discard side of the cut. Angle the torch head back 30 degrees or so with the nozzle pointed toward the discard side cut, then start the arc. Rotate the torch head vertical as the arc begins to penetrate, and begin cutting. This will allow the arc to bounce the blowback away from the consumable face. Keep in mind the arc should be directed to the discarded side of the cut or you will cause damage to the piece you are trying to keep. This is a fairly rapid motion. If it takes too long to pierce, you may have reached the practical limit for piercing. The practical piercing capability of almost any plasma cutter is limited roughly to ½ it’s maximum clean cut capability.

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