Posts Tagged ‘welder’

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Is welding possible underwater?

Wednesday, May 18th, 2011

This is a common question in the minds of many that are recently learning about welding. The answer to this, as a surprise to many is, yes! Welding can be performed underwater and underwater welding has been used for a long time to make quick repairs to parts of the ship that are underwater like the hull or the propeller. The process that is used underwater in wet conditions is known as shielded metal arc welding. This process makes use of a waterproof electrode. With the help of such techniques, repairs to a ship or a submarine can be done on the go without the necessity to dock the ship at a port all the time for repairs. Also welding underwater is possible by using friction welding techniques and also by using flux coated arc welding. With such possibilities, experiments are going on to carry out welding in greater depths on thicker materials.

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Gas welding

Tuesday, May 17th, 2011

Gas welding is also known as oxyfuel welding. This welding process makes used of the oxy acetylene gas for the process of welding. This welding process can be considered one of the oldest and most versatile processes of welding. Even if this welding process is not being used in industrial applications today, that have dropped this type of welding in favor of more modern technology, this welding technique is still broadly used for piping and repair work. The equipment that is used is relatively cheap. The arc that is produced is done with combustion of oxygen with acetylene gas. The intensity of the combustion depends on the ratio in which the gasses would be mixed. This can produce high wielding temperatures which can be used in a large number of applications. A similar method is also used in a metal cutting process that is known as oxyflame cutting process. This is used for the cutting of metals.

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Explosion welding

Monday, May 16th, 2011

Explosion welding is a solid state welding. In this, the two metals are joined by pushing them together under very high pressure. This is normally used for making pipes and tubes. The use of this form of welding is very limited because of the nature of the process that allows for only simple geometry. This type of welding technique can be utilized to join two metal pieces together that cannot be welded together using other conventional forms of welding. As with all solid state welding process, this process does not melt the metal. In fact it would only plasticize the surface of the two metals which are then pushed together under high pressure to come in intimate contact with each other to create a weld. With the use of this method, large areas of metal can be welded extremely quickly and the weld that is created is very clean. This method is however less used because of the expansive knowledge of explosives that are required to create the weld.

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Energy beam welding

Friday, May 13th, 2011

As the name suggests, the welding is done with the help of an energy beam. The beam of energy can be laser or an electron beam. This is a relatively new process that has gained a lot of popularity because of the high efficiency and the less amount of time that is consumed in the welding process. When talking about a laser beam, a highly focused beam of light is used for welding. In an electron welding setup, the metals to be joined is placed in a vacuum and a focused electron beam is used for welding the two pieces together. Both the laser and the electron beam have high density and this makes a deeper penetration possible. The processes are extremely fast and also can be automated easily. This makes the processes good for increasing the production rate. The initial costs and the cost of such equipment however are some drawbacks which has hampered its entry for regular use in the market.

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Costs and trends in welding

Thursday, May 12th, 2011

There have been massive changes in the industry of welding. Initially, the process of welding would mean large bulky units and massive drawing of power. Also there would be many health issues and very limited geometry on which the welds can be created. However with the advancements in technology, there have been so many changes in the world of welding that today almost anyone can pick it up as a hobby. There are many units available that are portable and make the whole process of welding easy. Also there is great emphasis given on cost saving and these machines are specifically designed to minimize the energy usage in the process of welding. The machines are made for precise welding so that there is less room for error. With development of highly evolved techniques of industrial welding like the laser welding or plasma arc welding the process of automating a welding line has become relatively simple.

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A brief history of welding

Wednesday, May 11th, 2011

When we consider the history of welding, we should consider the history of joining metals. This is because welding is essential the joining of two metals. This process dates back several millennia. As far as the Bronze Age goes, there has been always joining of metals to make structures or sculptures. It was prominent in Indian architecture as there have been many monuments that have been made out of metal and joined through the ancient forms of welding. The usefulness of welding has been quite prominent throughout history. Weapons, plates spoons etc. were all made from some form of welding or other. Nowadays through time, there have been a lot of changes and improvements in welding. This has been brought about due to the need of welding in our everyday life. Therefore the process of welding has become much more sophisticated and on many levels easy to handle than most other metal working processes.

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What is High tolerance plasma?

Monday, May 9th, 2011

Unlike in normal plasma cutting method in which there is no sharp or squireness in the edges we can get the right result that we need in this method. Getting an improved cut quality is no more difficult as we have High Tolerance Plasma Arc cutting, that are also known as HTPAC systems. These High Tolerance Plasma Arc cutting are obtainable with an extremely constricted plasma flow.

To be precise we can say that High Tolerance Plasma Arc cutting method is an automatic technique which requires accuracy, speedy tackle. We can get great results with thicker sheets starting from a minimal thickness of about 6mm.

Apart from this the cutting speed of these High Tolerance Plasma Arc cutting method is usually lesser than the usual plasma processes and can be calculated to be just about 60 to 80% the speed of a laser cutting method but still give a great cut at the end. The Cut quality lies between a usual plasma arc and the laser beam with Narrow kerf width. As the heat affected zone is very small, there is less or very minimal distortion.

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Water injection in the Plasma Arc Cutting Process

Friday, May 6th, 2011

As we all know water is used as a coolant in many industrial methods that involves high temperature for the process. Same ways water injection in the plasma arc cutting process also has a specific use. Water is injected through the injector into the plasma arc.

The plasma arc is generally got when Nitrogen is used as plasma gas in most of the plasma cutting machines. When the water is introduced to the plasma arc it induces a high degree of constriction. We can note that the temperature shoots up considerably to 30,000°C and above in this particular process.

If you compare the above process advantages with conventional plasma you can notice that there is a substantial Improvement in cut quality as well as squareness of cut. Apart from the improvement in cut quality we can also find an increase in cutting speed, less noticeable risk of double arching as well as decrease in nozzle erosion.

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Basics of Arc Welding

Tuesday, May 3rd, 2011

Welding is a very easy process to learn about. Arc welding and stick welding are one of the most basic and common welding techniques that are initially thought to every welding student. Arc welding can be thought in four basic steps.

Step1: Equip yourself with safety accessories before you enter the domain to weld. This is a must irrespective of what your experience in welding is. Even the most experienced, brilliant welder has to take care of safety precautions before he starts to weld.

Step2: Always work with clean metals. This is a preparatory stage of welding. Clean your work piece properly before you work upon it.

Step3: Check for the welding earth connection. Make sure it is good. You are mainly using electricity to carry out the task of welding and if your earth connection is not good enough, you are most likely to mess up the task. An area of potential problems can be eliminated

Step4: Strike the arc properly. This is one of the biggest concerns for any welder and there are only three possible ways to do it;

•    Flick up from an edge
•    Strike like a match/scratch it
•    Tap it straight down, then back up

Hold the rod as straight as possible.

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The Electrically Hazardous Areas While Welding

Monday, May 2nd, 2011

While you get to start welding, you will have to know about a few important stuffs like Safe Work Practices, Primary Electric Shock and precautions, Secondary Electric Shocks and precautions and more. This article is a short lesson about the Electrically Hazardous Areas that you will have to know before starting to weld alone on your home. If you are still practicing welding, it is advisable for you to learn all the possibilities in which one might fall into an accident and avoid them wisely.

Generally arc welding is electrically hazardous under the following conditions. If the location in which the welding is carried out is damp or wet, or on metal floors or surfaces, or if it is in restricted body positions of the welder when he is sitting, kneeling or lying, the probability of Accident is more.

The welding equipments which are best for carrying out arc welding under electrically hazardous areas is when you use Semiautomatic DC Constant Voltage welder or DC Manual welder or AC welder. All of them must be used with Reduced Voltage Control.

If you experience a shock the first thing you should o is to check your equipment for any malfunctions like disconnection in input power and take the machine to a qualified electrician to resolve it.

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