Posts Tagged ‘MIG 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.

Share

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.

Share

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.

Share

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.

Share

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.

Share

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.
Share

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.
Share

An insight into gas welding and its associated dangers

Thursday, April 12th, 2012

We all know what welding is all about. Theoretically speaking, it is an art where two or more metal pieces are joined together with the help of a molten solution that solidifies and forms the bond between the metal pieces. However, though it might seem as simple as it sounds, it is a highly complicated and daunting task that requires immense precision and concentration. Only then sturdy welds could be made which makes the overall end product far more versatile and comprehensive. Every professional welder is invariably good at it only because of his/her background practical experience and knowledge. Welding is one among the most complicated tasks you could ever undertake considering the vulnerability you are put through and all its associated dangers.

Irrespective of whether you are practicing welding with the help of MIG welder, TIG welder etc, it is highly imperative that you practice caution and exercise immense control. Never compromise upon safety measures at any point of time. As a dangerous task, it could even kill you when the severities of the wounds you get are of greater extent. Gas welding is especially one among the dangerous welding tasks you could ever undertake.  Oxyfuel safety is one among the most important features of welding and safety measures which is highly neglected during training. Gas welding fatalities have always been predominant due to the same reasons. You ought to purchase Oxyfuel welding kit by all necessary means without fail. This particular kit ensures you safety during all welding procedures. What can you do with it? You can weld, heat, braze, bend carbon steel and chormoly and literally do anything and everything that are most likely related to the field of welding. This particular kit is highly useful as you can also weld aluminum, cast iron, stainless steel and many other hard metals.

However, caution must be used while using these Oxyfuel cylinders as it can lead to several dangers. It can literally kill when caution is not practiced. However, it stands to be highly resourceful to perform all kinds of welding activities.

Share

Need to Know The MIG Welding Part2

Monday, April 9th, 2012

Gas cost is one of those hidden or difficult to assess parts of MIG welding. Invariably, the smallest possible gas cylinder is always the first choice for beginners, thinking they are getting out on the cheap.  But in reality, it can cost nearly as much to fill and maintain the smaller cylinder as it does the larger ones.  A small 80 cu ft.  Cylinder can be bought and owned relatively cheaply, but may only last three to four hours of limited welding.  Large cylinders are usually rented by the month or leased by the year, instead of sold.  A typical yearly cylinder lease cost can vary from 50-80 dollars per year.  But in reality, re- fill times are extended, and re-fill costs are not much more than refill cost of a smaller cylinder in many cases.  Additionally, depending upon your local welding supplier, the bottle you get back may or may not be your own, and hidden fees can be charged to you if you receive a cylinder that is at or near it’s inspection date.  Cylinder inspection dates are stamped on the neck. Depending on the test date, your next exchange may cost you an extra 60-70 dollars for a hydrostatic test of the cylinder before it can be filled.  If you lease a cylinder and an inspection is due this cost is always borne by the filling company, and not by the customer.  Any repairs additionally are carried out at the welding supplier’s expense.  Not so with a customer owned cylinder. If anything goes wrong with your cylinder, the cost of replacing a whole valve or even the cylinder itself is borne by the customer.

Share

The Benefits and Disadvantages of Flux Core

Thursday, April 5th, 2012

Flux core while similar to MIG in appearance, and basic operation, is very different in a couple of major areas. First, Flux Core as the name suggests uses a wire, with a flux based center. Instead of using a shielding gas, as the metal melts, the flux flows out and covers the weld, similar to the way a stick weld would operate.  Second Flux core is ideal for almost any outside welding, in breezes or in heavy drafts, because unlike gas, the flux is not easily blown off the weld.  Overall, it is a lot more dirty and messy to weld with, as spattering and smoke are constant reminders that you are Welding without a Gas to surpress it.  Flux Core can as a result of not having a gas flowing, achieve greater penetration.  But due to the high amount of spatter, transfer efficiency is reduced.  It is fast, as with MIG, but slower in some respects since more wire is consumed to make the same amount of weld that you would with a MIG.  Heavy weldments with thick plate metal, such as tanks, boilers, and even pipes can be made quite easily. Thinner welds, due to the extra heat are more difficult to manage though.  As far as expense, flux core wire can be more expensive to run, though the low initial startup cost of welding with a dedicated Flux core machine makes it initially more appealing.  The positive aspects of a wire with a cored flux versus solid wire with gas surrounding it appeals to many people especially beginners.  The absence of having to purchase or lease extra equipment just to get started reduces initial cost.  But over time the price paid for flux core wire, does eventually offset the initial savings of a cheap welder.  For most homeowners purchasing a Flux Core wire welder over a MIG welder, the main issue does seem to be start-up cost.  For those in the industry purchasing a Flux Core wire welder over a MIG, the issues seem to be simplicity, and capability out on a jobsite.

Share