Welder and Welding Methods

Welding has been used in thousands of manufacturing activities and is the most common means of permanently joining metal parts. Welders construct or repair metal products by sealing parts using different welding methods.

How Welding Works:

• Craig House, a First Class boilermaker welder and workshop manager, says that among the various welding methods used, manual metal arc welding or stick welding as it's known in the industry is a commonly used method.

• Arc welding involves two large metal alligator clips carrying a strong electrical current. One clip is attached to any part of the work piece metal part being welded while the second clip is attached to a thin welding rod. When the rod touches the metal part, a powerful electrical circuit is created.

Turn Up The Heat:

• The intense heat created by the electrical current causes the metal part and steel core of the rod to melt together.

• This cools quickly and results in a solid bond. During welding, the flux (welding wire) that surrounds the rod's core vaporises, forming a gas that serves to protect the weld from atmospheric elements that might weaken it.

Craig House unravels the process:

• Pressure vessels are round cyclinders which are to be welded longitudinally. The vessel will already have been tack welded by a boilermaker and after it is set up on rollers, run-off tabs are put on.

• These enable welders to continue welding past the end of the joint. It gets welded from the inside first, rotated and then welded from the outside.'

• Welders also join beams used in the constructing of buildings and bridges, and join pipes in pipelines, power plants and refineries.

Torch cutting and Gas welding torch

In the first case an employee intentionally put the nozzle of an unlit Torch cutting in his pants with the oxygen valve open. As soon as he re-lit the torch, the heat from the flame ignited his pants, causing severe burns to his body below his belt line.

The next incident occurred inside a small space located in a steel enclosure where a worker had been cutting with a torch. The worker turned off the gases with the valves on the torch before exiting the workspace. As he was lighting the torch after returning to the job, a minor explosion resulted in a short flash fire that severely burned the employee. The oxygen valve on the torch had not been fully closed, permitting oxygen to accumulate in the small space.

Most recently, an employee squirted oxygen into his glove to cool his hand. Sparks from a nearby metal saw being operated by a fellow worker ignited the glove, severely burning the torch bearer’s hand.

Pure oxygen supports rapid combustion of any burnable material. Materials in the presence of an enriched oxygen atmosphere can ignite with little warning. Oxygen must never be used for any purpose other than intended.

Vibra-Free High Speed Aluminium Machining

Spare-Parts in welding Machines

According to CNCA, spare parts that do not require a CCC Mark are exceptional cases. Article 2, 4 and 5 of *Document No. 8 * (not translated into English) contains the guidelines for CCC Mark exemptions. CNCA explains that a spare part is one whose function is part of the operation of a complete machine. Structurally, it must be combined with other parts to make a whole. A spare or replacement part that is to be assembled into a whole machine does not require a CCC Mark.

However, if the spare or replacement part is sold other than as a spare or replacement part for a specific machine, it would require a CCC Mark. For example, new parts used to replace a broken breaker, a faulty cable in a manufacturing tool or a non-functioning server power cord would be considered replacement/spare parts, while an entirely new machine used to replace a broken one would NOT be considered a replacement part.

For further clarification, to qualify as a spare/replacement part and the CCC Mark exemption, the part MUST be imported for a specific end-use. If the product is destined for re-export, it does not need a CCC Mark.

To clarify, products in the CCC Mark catalogue destined for re-export, though not requiring the CCC Mark, must apply for the CCC Mark exemption]/. If the spare or replacement part is destined for sale or use other than in a specific replacement function in China (and is listed in the First Catalog), it MUST have a CCC Mark.

Flame Cutting - Plasma Cutting Machines Manufacturers

Welders and cutters need good eyesight, good hand-eye coordination, and manual dexterity. They should be able to concentrate on detailed work for long periods and be able to bend, stoop, and work in awkward positions. In addition, welders need to be adaptable, as it is becoming increasingly common for welders and cutters to receive cross-training for other production jobs.

Welders, cutters, and welding machine operators held about 453,000 jobs in 1996. About 9 out of 10 welders and cutters were employed in manufacturing, services, construction, or wholesale trade. The majority of those in manufacturing were employed in transportation equipment, industrial machinery and equipment, or fabricated metal products. All welding machine operators were employed in manufacturing industries, primarily fabricated metal products, machinery, and motor vehicles

Welders and cutters are often exposed to potential hazards. They wear protective clothing, safety shoes, goggles, hoods with protective lenses, and other devices to prevent burns and eye injuries, and to protect them from falling objects.Welders often work in a variety of awkward positions, having to make welds while bending, stooping, or working overhead. In some settings, however, working conditions are much better and there are few hazards or discomforts. Overtime is sometimes necessary to complete special projects.

Cutters also dismantle large objects, such as ships, railroad cars, automobiles or aircraft. Some operate and monitor cutting machines is similar to those used by welding machine operators. Welders and cutters have need good eyesight, good hand-eye to coordination, and manual dexterity.

All welding machine operators were also well employed in manufacturing good industries, primarily fabricated metal products, machinery, and motor vehicles

Optimism among major generator brands

There are many types of generators like natural gas generator, Natural gas genset, Environment friendly generators manufacturers India, petrol generator, Diesel generator, petrol generator, natural gas generator.

Depending on the appliances that will be powered by chosse your generator type, you may need certain accessories for safety reasons. For example, if you want to use your computer, you’ll need UPS (unlimited power supply) to prevent data loss during transfer time.

Generators are becoming common industry equipments these days. Electricity or power should be constantly flowing in a manufacturing zone; else, revenues may be lost. Diesel generator can either be for home or industrial use. Areas that are subject to extreme weather where power outages usually happen are advised to install one. For industrial areas, generators are standard requirements.

Generators are specially designed to provide you uninterrupted power supply while you are in the remote corners of wilderness, where you can find no source of power. A standard diesel generator comes with approximately three times greater horse power (HP) than ordinary generators. Thus, this generator is characterized by low fuel consumption with high energy output.

Types of Weldings

Table 1. Weld Characteristics/Parameter/Criteria for Three Types of Welding

CHARACTERISTIC OR PARAMETER	RECOMMEND OR STANDARD PRACTICES
	GAS TUNGSTEN ARC WELDING (2219 Al)	VARIABLE POLARITY PLASMA ARC WELDING (2219 Al)	ELECTRON BEAM WELDING (INCONEL 718)
Preferred Position	Flat	Vertical	Flat
Shield Gas	Helium (99.999% Purity)	Helium (99.999% Purity)	Vacuum
Plasma Gas	N/A	Argon (99.999% Purity)	N/A
Backing Required	No	No	In Some Instances (1)
Preferred Electrode	2% Thoriated Tungsten	2% Thoriated Tungsten	(Tungsten Filament)
Appropriate for Repair	Yes	Not Usually (2)	Yes
Cleaning Requirements	Mechanical Removal of Oxide, Free of Hydrocarbons	Mechanical Cleaning Not Required, Degrease Only	Special Cleaning for Vacuum Requirements
Used for Tack Welding	Yes	No	Yes
Computer Control	Desirable	Essential	Desirable
Most Prominent Potential Defects	Oxide and Tungsten Porosity, Lack of Penetration or Fusion	Undercut, Lack of Fusion	Improper Seam Tracking, Microfissuring

The Ternary Gas Plasma Weldings Torch

Electron-beam welding has many advantages over other welding techniques. One of the prime advantages of electron-beam welding is the ability to make welds that are deeper and narrower than conventional welds. A second advantage is higher welding speeds, which are due to the high melting rate associated with the concentrated heat source.Electron-beam welding has many advantages over other welding techniques. One of the prime advantages of electron-beam welding is the ability to make welds that are deeper and narrower than conventional welds.

Present-day electron-beam welding is performed in a vacuum chamber, limiting the size of the work piece that can be welded. Maintaining the vacuum requires pumps that use a lot of electricity and special, expensive lubricants that must be disposed of as waste.

Hershcovitch said, This grant provides the opportunity to commercialize the plasma window that I started to design a decade ago. I am very pleased that Acceleron will work on testing it and bringing it to the marketplace. I expect that it will be a commercially successful energy-efficient device.

In present-day technology, an electron-beam welder consists of an electron gun enclosed in a vacuum box that can be as large as a room but is generally much smaller due to efficiency considerations. In contrast, in the new non-vacuum electron-beam welding method, the plasma window is mounted on the electron gun and maintains the small vacuum area needed to propagate the electron beam.

The plasma window is about 40 times as hot as the air at room temperature. This intense heat makes the ionized atoms and molecules move around faster and collide more often with air molecules, thus stopping most of them when they try to cross the plasma window.

Hershcovitch likens the plasma window to the force field window in the shuttle bay area of the Starship Enterprise in Star Trek. The force field separates atmospheric pressure in the Enterprise from the vacuum in outer space. In the plasma window, hot ionized gas particles are trapped by electric and magnetic fields. The particles, like any gas, exert pressure, which prevents air from rushing into the vacuum chamber housing the electron gun.

Mig Welding Machines Arcs

A new generation of arc welder has recently become widely available at a price which is within reach of most amateurs and part-time mechanics, known as the MIG welder (metal-arc inert gas welder). In MIG welding the arc is ensheathed in a stream of inert gas which prevents the molten metal from oxidising.The stream of gas changes the character of the emitted radiation, and it is possible that this type of welder poses a greater threat to sight than previously recognised. Radiation in the ultraviolet range emitted by arc welders is absorbed by the unprotected cornea and lens, giving rise to a keratoconjunctivitis, or 'arc-eye,' which, though intensely painful, is not considered a threat to sight.Radiation in the visible and near infrared spectrum, however, penetrates the eye to be absorbed by the retina and may cause thermal or photochemical damage which may be permanent and sight-threatening. Retinal injuries resulting from exposure to ordinary electric welding arcs have been reported, but such injuries are uncommon.

Two cases of retinal burns resulting from exposure to MIG welder emissions which presented on consecutive days to the Leicester Royal Infirmary are presented. This is the first report of such injuries relating specifically to MIG welder.

Mig Welding-Push Technique

Pulsed Mig Forms:

The setting current lowers taken as a whole heat input addressing the burn-through and warp issues commonly associated with spray transfer MIG

Process	Volts	Amps	Travel speed (in. per min.)	Heat Input (KiloJoules/in.)
Spray MIG*	18.0 V	94 A	24 IPM	4.23 Kj/in.
Pulsed MIG*	18.0 V	69 A (average)	19.5 IPM	3.82 Kj/in.

Tips for Welding, Cuttings and Brazing

* Safety and Health Fact Sheets: American Welding Society Fact Sheets covering aspects of safety and health applicable to welding and cutting. Includes subjects such as fumes and gases, radiation, noise and electrical hazards. Produced by the Labeling and Safe Practices Subcommittee of the AWS Safety and Health Committee.

* Electric Welding Safety: Workplace Safety and Health Division of the Manitoba Labour Department, Worksafe Bulletin Provides a short description of the hazards associated with electric arc welding and protective measures.

* Arc Welding Safety: University of Arizona College of Agriculture. The electric arc welder remains one of our most useful and timesaving pieces of shop equipment. Properly installed and used the arc welder is very safe, but if used improperly the operator can be exposed to a number of hazards, including toxic fumes, dusts, burns, fires, explosions, electric shock, radiation, noise, and heat stress.

* American Welding Society: The American Welding Society was founded in 1919 as a multifaceted, nonprofit organization with a goal to advance the science, technology and application of welding and related joining disciplines. Headquartered in Miami, Florida, AWS serves more than 48,500 members in the United States and around the world.

* NIOSH Strategic Research on Welding Identifies Data Needs: Some studies suggest that occupational exposures to welding fumes may pose the risk of serious respiratory, neurological, and reproductive effects. However, the available data generally are too limited to offer conclusive answers. Thus, scientists and policymakers face a need for more and better data.

* Welding Fumes Sampling: This summary prepared by MSHA provides guidance on hazards associated with welding and procedures for chemical sampling.

* Control Technology Assessment of Welding Operations A field study performed by identify, observe, and evaluate engineering control measures that may reduce the amount of fume a worker is exposed to during welding. Includes photos and figures of local exhaust systems.

Arc-Welders

All arc welding and cutting cables shall be of the completely insulated, flexible type, capable of handling the maximum current requirements of the work in progress, taking into account the duty cycle under which the Arc welder or cutters is working.

Any current-carrying parts passing through the portion of the holder which the Arc welder or cutter grips in his hand, and the outer surfaces of the jaws of the holder, shall be fully insulated against the maximum voltage encountered to ground.

Only cable free from repair or splices for a minimum distance of 10 feet from the cable end to which the electrode holder is connected shall be used, except that cables with standard insulated connectors or with splices whose insulating quality is equal to that of the cable are permitted.

Multi Purpose Units

Introduction: Large power reserve, driving multi machine and electric appliance; small volume, light weight; compact structure, simple operation, convenient maintenance and low noise.

Multipurpose structure, convenient maintenance, economic burnt oil, light weight, few blowdown, stable operation and reliable performance.

Cutting Products announce the newest multi-purpose welder in its X-Series column. Designed for outstanding ease of use and manage,the MTS 3500i is a multi-process, fourth generation inverter power resource that combines consistency and ease of use in a controlling, versatile pack up. The MTS 3500i offers outstanding welding capabilities for MIG, TIG or Stick welding.

Multipurpose structure, convenient maintenance, economic burnt oil, light weight, few blowdown, stable operation and reliable performance, suitable for power generation, irrigation, tour, field operation, recreation areas, farm machinery etc.

Motorsports

• Options for grant or other funding to assist Motorsport groups to improve services or to conduct events;
• Governance and management models for Motorsport facilities;
• Funding models and propose an detailed allocation breakdown of the ACT Motorsport Fund consistent with the Government’s directions;
• Opportunities to increase participation rates and to host national and international events in the ACT;
• Cost infrastructure requirements for a Motorsport precinct; and
• Options and broad requirements for an off-road recreational motorcycle riding facility.

Multi-purpose Motor sport and driver training facility in Townsville took a step forward today

"This decision today is a progressive step towards finding a home for the complex and I`m sure it will be welcomed by the various motor sport groups who have been working towards this facility for many years."

Licenses under the Motor Vehicle Sports Public Safety Act 1985 are required for all motor sport events conducted on private property only non public roads. Motor sport events which are conducted on public roads are not required to be licensed under this Act, but are required to be formally approved by the RTA and NSW Police Service under the Road and Transport Legislation.

Permits under the Mount Panorama Motor Racing Act 1989 are required for all motor sport events conducted at Mount Panorama, Bathurst utilising the full 6.32 km circuit public road. Motor sport events which are conducted on a part of a public road not the full circuit are not required to be permitted under this Act but are required to be formally approved by the RTA and NSW Police Service under the Road and Transport Legislation.

Pulsed Mig tigs

1. Weld in a well-ventilated area. Welding fumes should be ventilated away from the person welding, not across the welder's face. Remember that shielding gases are asphyxiants, and welding fumes are harmful. Work in well-ventilated areas to prevent suffocation or fume sickness.
2. Never wear synthetic fiber clothing or weld with flammables in your pocket. Synthetic fibers are highly flammable. If ignited by a welding spark, flammable i.e. matches, butane lighters, fuel sticks, etc. could cause serious burns. Do not allow bystanders to smoke in the welding area.
3. Use both hands. To reduce fatigue, use both hands for welding.
4. Handle hot metal with pliers or tongs. Submerge hot metal completely in water to prevent steam burns

Joining and cutting of metallic materials and the welding of thermoplastics i.e.: conventional and pulse arc welding and surfacing; electron beam welding and laser welding and cutting; resistance, friction and friction stir welding; brazing and soldering; thermal cutting; joining of thermoplastics.
Some of the most recent research works are as follows: weldability of corrosion-resistant nickel-based alloys; weldability of a modern thermomechanically rolled steel; joining of the heat resisting steel; properties of welded joints after long-term operation;

• Axes: 6
• Payload: 6 kg
• V-Reach: 3398 mm
• H-Reach: 1885 mm
• Repeatability: ±0.06 mm
• Robot Mass: 285 kg
• Structure: Vertical jointed-arm type

SPECIFICATION
MODEL	PULSE TIG
INPUT	415 VAC 1 Phase
CURRENT	42 A
OUTPUT	300A
O.C.V.	80 V
DUTY CYCLE	60%

Welding and cutting 1005 TLF 3800 TRUMPF; welding systems for recording and processing of welding parameters; thermal- and stress-strain cycle simulator; computers programmes for research, engineering calculations, design of experiments and Finite Element Analysis.

Metal-Cuttings

• Part Number:	1915
• Part Title:	Occup. Safety and Health Standards for Shipyard Employment
• Subpart:	D
• Subpart Title:	Welding, Cutting and Heating
• Standard Number:	1915.54
• Title:	Welding, cutting and heating of hollow metal containers and structures not covered by 1915.12.

1915.54(a) Drums, containers, or hollow structures which have contained flammable substances shall, before welding, cutting, or heating is undertaken on them, either be filled with water or thoroughly cleaned of such substances and ventilated and tested. 1915.54(b) Before heat is applied to a drum, container, or hollow structure, a vent or opening shall be provided for the release of any built-up pressure during the application of heat. 1915.54(c) Before welding, cutting, heating or brazing is begun on structural voids such as skegs, bilge keels, fair waters, masts, booms, support stanchions, pipe stanchions or railings, a competent person shall inspect the object and, if necessary, test it for the presence of flammable liquids or vapors. If flammable liquids or vapors are present, the object shall be made safe.

Consider the parts of a toaster, such as the metal lever that lowers the toast. These parts, and many other metal products, are produced by machine setters, operators, and tenders—metals In fact, machine operators in the metalworking and plastics industries play a major role in producing most of the consumer products on which we rely daily.

In general, these workers can be separated into two groups—those who set up machines for operation and those who operate the machines during production. Setup workers prepare the machines prior to production, perform initial test runs producing a part, and may adjust and make minor repairs to the machinery during its operation. Operators and tenders primarily monitor the machinery during its operation; sometimes they load or unload the machine or make minor adjustments to the controls.

Machine setters, operators, and tenders—metal set up and tend machines that cut and form all types of metal parts. Setup workers plan and set up the sequence of operations according to blueprints, layouts, or other instructions. Often this involves loading a computer program with instructions into the machine’s computer controls. On all machines, including those with computer controls, setup workers respond to problems during operation by adjusting the speed, feed and other variables. They also choose the proper coolants and lubricants and select the instruments or tools for each operation. Using micrometers, gauges, and other precision measuring instruments, setup workers compare the completed work within the required tolerances

Plasma Cutter

Welder Weldings

Welding has been used in thousands of manufacturing activities and is the most common means of permanently joining metal parts. Welders construct or repair metal products by sealing parts using different welding methods.

The intense heat created by the electrical current causes the metal part and steel core of the rod to melt together. This cools quickly and results in a solid bond. During welding, the flux welding wire that surrounds the rod's core vaporises, forming a gas that serves to protect the weld from atmospheric elements that might weaken it.

The three other more common welding methods are flux cored, submerged Arc and TIG welding. MIG and oxy-acetylene are some of the other methods used. The type of method used depends on the the type of work being undertaken. For example, flux cored welding is typically used for shipbuilding activities whereas all four of the more commonly used welding methods may be used during the construction or repair of pressure vessels.

Welders are often exposed to a number of potential hazards such as the intense light created by the welding arc, and hazardous fumes and burns. Safety goggles with protective lenses and safety shoes must be worn. Because welders also work on outdoor construction sites where scaffolding is used, safety is a primary concern. Welders also work indoors in production or repair shops.

It was generally observed that welders in Calabar, Nigeria did not always wear their protective goggles during welding. Since chronic exposure to welding light can impair vision this study was done to assess the effect of exposure to welding light on ocular function of welders in Calabar, Nigeria. There were 195 subjects comprising 110 welders and 85 control subjects. Both groups were all male and had similar age range.

The tests employed were clinical examination for ocular disorders, assessment of visual acuity, and opthalmoscopy. Test questionnaire was also used to record information on length of service, precautionary measures at work place, age and past ocular illnesses.