Useful tips for Wire Feed Welders:

Wire feed welding, which not like stick welding uses a wire flux to reinforce its weld, consists of two main types, first one is metal inert gas and second one is flux-cored wire welding. MIG welding gives a best overall appearance, as it causes fewer spatters, and works best with thinner materials. MIG welding needs more tools than flux-cored welding, however, as it uses an inert gas to shield the weld. Flux-cored wire has the protect built into it, but can only be used with soft steel.

Wire Extension:
Maintain your wire sticking out of the tip of the contact tube as MIG welding. One-fourth to 3/8 of an inch of cable should expand out at all times as you work, suggest the Everlast Welders website.

Wire and Metal Thickness:
When welding a slim metal, use thinner cable; use thicker cables for thicker metals. You may also require different sized machinery, based upon the size of the metal you are welding. Welding machines will regularly come with these specifications.

Wire and Metal Matching:
According to Everlast Welders, the cables you use should match the type of metal that you are welding; for ex, use aluminum cable to weld aluminum and steel cable to weld steel.

MIG Welding Gases:
Use carbon dioxide as your shielding gas as MIG welding on steel. Everlast Welders suggests using 75 percent argon and 25 percent carbon dioxide for slim steel, and argon gas alone to weld aluminum. For stainless steel, experts suggest a triple-mix of helium, argon and carbon dioxide.

Flux-Cored Wire Welding:
When welding with flux-cored cable, maintain your cable as dirt free and dry as you can. In addition, when you complete a weld, clean off the slag, or debris, from the top of the weld. A chipping hammer and a cable brush work fine for such cleaning.

Welding & Cutting Safety Tips:

Cutting and welding of metals involve the application of high temperature to the things being welded or cut. This powerful high temperature is obtained from the use of inflammable gases, (ex., acetylene, hydrogen, etc.) or electrical energy. The intense welding warmth and the sources employed to create it can be potentially dangerous.

Therefore, to guard persons from damage and to guard building and gear against flames, etc., a set of advices about safety and health actions for the welders and those worried with the safety of the tools, etc., have been published by ISI and several other similar but International organizations.

By keeping in mind the following suggestions or precautions, the risks linked with welding can be mostly reduced. So, it is recommended that the beginner in the field of welding have to go through and become well-known with these suggestions which also have been discussed below:

1). Security advices for installation and operation of Gas welding and cutting tools.
2). Security advices for installation and operation of Arc welding and cutting gear.
3). Explosion, fire and additional hazards and defense against them.
4). Protection of welders.
5). Ventilation and health safety.

MIG Welding Advantages and Disadvantages:

Advantages of MIG Welding:

• The most excellent option when cosmetic appearance is an issue since it provides lesser spatter levels than flux-cored. The arc is soft and fewer likely to burn through slim material.

• The lesser spatter connected with MIG welding also means no slag to chip off and quicker cleaning time.

• MIG welding is the simple type of welding to study and is more forgiving if the operator is somewhat unpredictable in holding arc length or providing a stable travel speed. Procedure settings are more forgiving.

• If you are skilled and get exact correct guns, shielding gas, liners, drive rolls, and electrode, MIG can weld a wider range of material including thinner resources and different materials like stainless, nickel alloys or aluminum.

Disadvantages of MIG Welding:

• Since a bottle of outside shielding gas is necessary, MIG welding may not be the procedure of option if you are looking for something that offers portability and convenience. MIG also needs extra equipment such as a hose, regulator, solenoid (electric valve) in the wire feeder and flow meter.

• The welder's initial job is to arrange the surface by removing paint, rust and any surface contamination.

• MIG has a soft arc which will not correctly weld thicker materials (10 gauge would be the highest width that MIG could soundly weld with the 115 volt compact wire feeder welder we are referring to or ¼" with the 230 volt input compact wire feeder welder.) As the thickness of the material (steel) increases, the danger of cold lapping also increases since the heat input wanted for good fusion is just not possible with these small machines.

Tips to Use Welding Machines:

1). Decide the most excellent welding machine for your requirements.

2). Use a motor-generator welding machine in areas with no electrical energy. These types run on electrical energy, gasoline or diesel fuel and can make straight or alternating current.

3). Use an alternating power transformer machine for small industrial, garage or shop welding. These models are reasonably priced, lightweight and compact.

4). Consider rectifier welding equipment for jobs requiring both alternating and straight current. An easy flip of a switch permits the operator to decide the correct current for the job.

5). Make use of an electrode negative equipment if you are welding carbon and/or stainless steel. These types, powered by either diesel fuel or gasoline, are famous in construction work.

6). Clamp the ground wire to your workbench or straight to the thing you are welding. This produces sufficient heat and prevents damage to the welding equipment and its wires.

7). Consult the manufacturer's instruction guide for how to use your exacting type of welding equipment.

8). Clean your welding machines with a steel brush, chemicals or a power tool after each use.

9). Wear correct safety gear when using welding equipment, including a helmet, gloves and protective eye gear. Forever work in a well-ventilated region.

Spot Welder Advantages Limitations & Applications:

Advantages:

* The procedure involves smaller amount maintenance money.
* Ability of the worker does not influence the quality of spot welds obtained by this procedure.
* The process is usually free from burn and splash.

Limitations:

* To achieve small cost of building, the weld manufacture cost is not very high.
* The procedure proves uneconomical as compared to resistance spot welding where the latter are able to be simply employed.

Applications:

The use of physically operated arc spot welding gun is an ordinary thing in a variety of industries. Arc spot welding is particularly applicable for situations where resistance spots welding wants high pressure, high currents, does not have simple access and therefore fails to weld.

Arc spot welding torch be able to also be working to make holes in plates up to 3 mm broad or consequently. After the arc has impinged on the plate for a exact time, high force inert gas blows away the molten metal leaving a hole in the plate. Additional applications of, the process are in:

1. Automobile manufacturing.
2. Manufacture of sheet metal goods.
3. Assemble sheet metal to steel structures.
4. Manufacture of pulleys.
5. Joining killed carbon steel, low alloy steel, high alloy steel, titanium, etc.

Why TIG Welding Is So Popular:

TIG welding is a very accurate process that gives extremely clean welds with no splash and small amount of smoke. This makes it extremely beautiful for highly cosmetic applications, such as automotive, sculpture, experimental aircraft, and home-hobbyist jobs.

TIG welder is normally used in applications that have thin-gauge parts of stainless steel, chrome-moly tubing or lighter metals such as aluminum, and copper alloys. These thinner resources need exact heat control to prevent warping or burn-through of the foundation metal.

TIG welder machines efficiently function at the lower amperages that are wanted to give that control.

Short note on Basic arc Welding Circuit:

The fundamental arc-welding circuit is demonstrating in the image. An AC or DC power source, fixed with whatever controls may be wanted, is linked by a work wire to the work piece and by a "hot" cable to an electrode controller of a few type, which makes an electrical contact by the welding electrode.

An arc is formed across the gap when the energized circuit and the electrode tip touches the work part and is withdrawn, yet still with in close contact.

The arc creates a heat of about 6500ºF at the tip. This high temperature melts together the base metal and the welding electrode; creating a pool of molten metal sometimes called a "crater." The crater solidifies behind the electrode as it is moved along the joint. The outcome is a fusion bond.

Benefits of TIG welding electrodes:

• Make easy arc starting
• Enlarge arc stability
• Get better current carrying capability of the electrode
• Decrease the risk of weld contamination
• Boost electrode life

Oxides used are mainly zirconium, thorium, lanthanum or cerium. Added extras are usually 1% - 4%. These oxides very much increase arc initiation, particularly when direct current (DC) welding is working. Thorium oxide (thoria) has been used for a lot of years, have been establishing effective in terms of extended life and thermal competence. Zirconium oxide (zirconia) has been usually used for alternating (AC) TIG welding, usually for welding aluminum.