EBW (Electron Beam Welding) Repair of a Discarded Casting:

Regular welding would not be a satisfactory solution. But Electron Beam Welding a spare bushing in place, while expensive, may recover the cost previously invested in the finished and discarded part.

By welding in place a spare sleeve the procedure has the possible:

• of exactly focusing the beam on top of the joint, in spite of the distance,
• of introducing the small amount of warmth, avoiding spoil to mechanical properties and preventing intolerable bend,
• of creating a slim and deep, exactly located weld seam,
• of avoiding the require for frequent warmth treatment,
• of permitting thorough non destructive testing to be eligible the repair,
• of being performed within the shortest turnaround time limiting the delay in delivering a substitute part.

Welding Methods:

There are three types of welding methods to consider. They differ by speed and cost. The methods are all available to all welding and hardfacing products. However, specific products often have properties that are somewhat unique and not exactly duplicated when utilized by a different process.

Stick Welding:

Manual or stick welding requires the least amount of equipment and provides maximum flexibility for welding in remote locations and in all positions. Typically, each rod permits welding for about one minute. In seconds, one can change from mild steel to stainless to hardfacing. In seconds, the electrode can change from small to large diameter for small or large welds. Although simplest, this type of welding takes the greatest operator skill.

Semiautomatic:

This type of welding uses wire feeders and continuously fed electrodes. The welding gun is hand-held by the operator. The gun keeps feeding wire as long as the trigger is depressed. This is also much easier to learn than stick welding. This type of setup is becoming more popular on farms, which do more than minimal repair work. Semiautomatic welding increases deposition rates over manual welding because there is no need to stop after burning each rod.

Automatic:

Requiring the greatest amount of initial setup, automatic welding has the highest deposition rates for maximum productivity. The welding gun is carried by a mechanized carriage and the welding operator just pushes a start button. This would rarely be found on a farm, but is common at repair centers for heavy equipment that would rebuild your parts for you if the schedule was mutually acceptable.

Welding Project Ideas:

Thanks to the ongoing processes of technology - which, after something has been invented, tend to steadily simplify it, make it cheaper, and make it more suitable for general use through miniaturization and suchlike developments - welders are now available to the general public at a relatively inexpensive cost. Compact, high-quality, low-cost portable welders are now marketed which offer any handyman or tinkerer the opportunity to make use of this extremely convenient joining method.

The uses of welding are many and varied, ranging from the aesthetic to the practical, from small, intricate objects to large ones such as the frames for light outbuildings. A welder can be used in automotive work, for example. Resistance spot welding is often used to fit sheet metal patches into body panels where areas of rust or severe damage have been cut away, using resistance spot welding technology because ordinary spot welders cannot touch both sides of many car panels due to their being welded to the frame. MIG welding is often used for fixing patches in place as well, with initial spot welds to tack the new metal in place and a continuous weld to finish the job off.

Welding Procedures:

There are five basic steps when welding that must be followed.

• Proper Preparation - You first need to ensure that the metal you are welding is clean and dry. Remove rust, dirt, grease, oil and other contaminants by wire brushing. If not removed, these contaminants can cause porosity, cracking and poor weld deposit quality. You must also remove badly cracked, deformed or work-hardened surfaces by grinding, machining or carbon-arc gouging.

• Proper Preheat - The combination of alloy content, carbon content, massive size and part rigidity creates a necessity to preheat in many welding or hard facing operations. Most applications require preheating, as a minimum to bring the part to a room temperature of 70ƒ-100ƒ F. Medium to high carbon and low alloy steels may require higher preheat to prevent under bead cracking, welding cracking or stress failure of the part. Preheating can be done with a torch, oven or electrical heating device. Special temperature-melting crayons can help you verify proper preheat. Too much heat and you can often ruin alloy materials!

• Adequate Penetration - Correct Welding Procedure - Identify the correct amperage, travel speed, size of weld, polarity, etc. Make sure the completed weld meets your expectations in regards to size and appearance. Welds should be smooth and uniform, free from undercut or porosity. If possible, watch a video showing the type of welding you will be doing so you know what things are suppose to look like.

• Proper Cool Down - Preheating is the most effective way of slowing the cooling rate of massive or restrained parts, which are inherently, crack sensitive. Insulating the part immediately after welding with dry sand, lime, or a glass fiber blanket also helps minimize residual cooling stresses, weld cracking and distortion. Never quench a weld with ice or water as this will lead to greater internal stresses and potentially weld cracking.

• Post Weld Heat Treatment - Some items may require tempering or heat-treating. What this means is that you warm the item up with your torch after welding and allow it to slowly cool.

Five Ws of Welding: (Part - 2)

When was the welding process formed?

This process was formed before several millennia and the earliest examples are Bronze Age and Iron Age and middle age is the period that brought some advances in welding. In the year 1540, the vannoccio published the descriptions that include forge operation. In 1802, the Russian scientist proposed the practical applications of electric arc that also includes welding. In world war, the welding processes were widely used and 1920 was the year in which some major advances in welding technology and machines were used.

Who uses the welding processes the most?

As stated in the starting of the article, the manufacturing industries use this process the most and industries like, ship building, aircraft, motor manufacturing, automotive industries, electronic industries and in construction industries the welding process is widely used.

Where to get efficient welders?

Search in internet, you get a variety of manufactures who provide these welding machines in a quality and efficient way. Search for the best products in the market and also, before buying those machines, make sure that you get the machines that are quality and that have efficient duty cycle.

Revolution of Welding tools in the industry(part-3):

Accessories are the welders protection:

Welders are the people who are running in heat and have the ability of revealing to flame. So the welders should be sheltered well by garnishes such as gloves and helmets. Helmets protect the welders from the blast of heat to eyes. Helmets survive in different sizes and varieties.

Consumables the division of welding tools:

Consumables are the small tools which are used all along with welding tools. For different kinds of welding various consumables are used such as plasma consumables, mig consumables, tig consumables and tungsten.

Generators the option for electricity:

To run a business profitably continuous power supply is required. Generators are the substitute for electricity, they provides electrical energy when there is no power supply. Generators arrive in economy, deluxe and super generators based on the cast and purpose. Silent diesel generators have more features with 1000 hours of guarantee and it can be used for both residential and commercial purpose.

Revolution of Welding tools in the industry(part-2):

Venture techniques in welding tools:

While buying the welding tools various aspects should be measured such as its function (ie) where you are use and for what substance it's going to be used. While buying, check the welding tool should be proper in size.

Modern products are the money-making products:

The aim of every industry is to give a quality product and to gain profit. To earn highest profit the equipments should be a modern one and should formulate the work easier. Spot welders tig welder's wire feeders and multi system is the tool with some superior design makes the work easier.

Plasma cutters the new discovery:

Plasma cutters have its basis in the world war itself. It is used to engrave the steel and metals with high width. When you decided to purchase the plasma cutter a variety of factors should be considered such as its function cycle and for what reason you are going to use either use it in the industry are going to take it along with you. Many power plasma sequences survives such as power plasma 50, power plasma 70 and power plasma 60 which is used for different functions.

Revolution of Welding tools in the industry(part-1):

Welding is the method of joining the metals. Modern industries generally depend upon welding process. In olden day's welding process is the hard task and the same welding process is used for different types of metals. Due to the scientific improvement several welding tools and techniques came into the marketplace which offers you the greatest performance. You can see the well-known American statue is too made by welding process.

Welding tools are the back bone of the current industry:

When you decided to initiate an industry you should focus on the products which is necessary for the products should be efficient and a quality one. The most significant tool of welding is welder and welding equipments. Welding equipments like arc tig plasma cutters and trimmings such as welder gloves helmets are the most essential tools for the Welding industry.

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.

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.

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.

Tips and Tricks for Stick Welding:

Following are the some tips and tricks to assist get better your stick welding skills:

Select the correct electrode:

A lot of welders are not sure of the type and size of the electrode that must be used in stick welding. The dimension of the electrode you select ought to match the circumstances you are welding within and the kinds and thickness of metals.

Polarity matters:

If you buy an A/C only welding gear, then you require getting stick welding rods that are specially shaped to weld on A/C. Stand in mind that not all stick welding rods are shaped the same.

Do not use odd sizes for your metal:

Many metals come in exact sizes that are ordinary. These metals are a set easier to find and you be able to weld them earlier and much efficiently. You do not require to experiment on your metal assortment when it comes to stick welding.

Be familiar with your arc length:

For a winning stick welding job, you require to use an arc length that is the similar distance from the metal as the thickness of your electrode. For example, if you have an electrode that is ½ inch thick, then contain your arc ½ inch thick as fine. Do not fail to remember that as you use the stick electrode, you will want to move it closer to the metal.

Use of best auto darkening welding helmet makes you a improved stick welder:

A best auto darkening welding helmet is very significant in stick welding. The majority experts advised a welding helmet that darkens in 1/20000 seconds, be able to be attuned from 9 to 12 shades, and has delay and compassion features. You want a best welding helmet for you to see obviously where you are striking your arc and to alone will make you a best stick welder. Sideways from that, it is able to also guard you from the injurious UV and IR emissions from the arc.

Tips for Spot Welders:

Spot welding tips require be sizing and matching to the exact thing that is being welded. The many styles of tips permit for the welding of a lot of sizes and types of metal. The key to finding a best brand is finding a tip that has best conductivity and is completed from a very pure alloy. This will permit the tip to reach the maximum temperatures and not deform.

The most common spot welding tips types:

Truncated cone, radius faced angled straight tip, offset nose, sharp nose, dome nose and flat nose. Truncated cone tips seem like a 45-degree cone with the top compressed out. Radius face tips are rounded crossways the entire tip in a 45-degree arc. Angled straight tips are tips that come to a in a straight line point and contain a 30-degree viewpoint cut crosswise them. Offset tips have one in a straight line edge that come flat nose tip with 45-degree viewpoint. A point nose tip comes to a point with a flat welding face. A dome nose tips have a half circle tip with a very little welding face. Flat tips are totally flat with the complete tip being the welding face.

Tips for TIG Welding:

Anybody who has worked by TIG Welders and automatic and orbital TIG systems, knows the TIG weld quality is highly needy on retain the shape and excellence of the tungsten tip. Weld begin data is dangerous with automatic TIG welding applications. Tungsten life is better with a begin ramp up from a low current begin point then ramp to the operating power.
The PowerTig 315DX power source is shown above. This is one of the most excellent, cheap, Adjustable weld parameters for 2t/4t operation. Connect to clean power generator for "go anywhere" capabilities. Easy to connect torch and accessories allow quick setup. The equipment delivers reliable, controlled weld results and the company that provides the gear provides brilliant gear product support.

For automatic TIG welds with AVC controls or high-quality tungsten to work height control, with the use of right tungsten dimension and weld parameters, both a tungsten point and a tungsten with a little flat spot with a 20 to 30 degree angle be supposed to be able to obtain the tungsten through at least a high duty 6 to 8 hours of arc on time with no tungsten regrind or modify.

Welders Clothing:

Since welding produce powerful heat and burning sparks that may cause serious burns, it is important to dress in the correct work clothing. The following describes the type of clothing suitable for welding process.

Welders Shirts:

Welders Shirts must be made of thick weighty cloths such as heavy cotton or denim that is not simply burned. The Welders shirts have to be long sleeved and must not contain pockets if they contain button flaps on them. Open pockets might catch burning sparks or globules of hot metal that can burn the skin. The Welder shirt ought to not contain frayed ends that sparks from welding can simply catch fire. The Welders work shirt must not have any torn areas that permit hot sparks to go through. Don’t have Matches, lighters, or paper materials in shirt or pants pockets in the time of welding.

Welders Pants:

The Welders pants must be close fitting and prepared of a weighty cloths such as work jeans. Overalls are suitable if other clothing is worn in them. The Welders pants must be long sufficient to cover the top of the boots and contain no cuffs that may trap sparks or burning slag. Like the shirts the pants are supposed to contain no frayed ends or torn areas in them. It is suggested not to have metal keys or other devices dangling from the pants that can arc against the work area.

Welders Boots:

High top leather boots are necessary for welding and common shop use. Canvas boots or clothing shoes should not be damaged. The boots is supposed to fasten all the method up to stop sparks falling into them. Leather laces that will not simply burn or smolder must be used. Dress in heavy work socks not nylon or thinner socks for additional guard against sparks. Security boots with strengthen toe caps are suitable for welding shops and work to defend the feet. Spats or leggings are leather pieces that fit over the top of the boot to stop sparks falling into the boots and are available at welding provide stores.

Welders Caps:

A Welder cap or few form of head covering must be used for welding, particularly in other than the flat place. The cap has to be companionable with the welding head equipment called the welding helmet. Welder’s caps or welders beanies (cap with no peaks) are available from all welding equipments providing stores.

Safety Tips for Welding:

There are some rules you should follow as you are welding/hard facing:

• Protect yourself from fumes and gases - for all time weld in an open, fine ventilated space and stay your head away of the fumes, particularly by hard facing.

• Dressed in protective clothing - Protect your eyes and face with a welding helmet designed for arc welding, not simply gas welding safety glasses. In the similar way, guard your body from weld spatter and arc flash with woolen or cotton clothes, a fireproof apron and gloves, and boots. In addition make sure to protect others nearby you from the arc rays as well.

• Beware of electric shock – Don’t touch exist electrical parts and make sure to your welding machine is correctly grounded. In no way weld if you are wet or if your gloves contain holes in them.

• Fire/explosion hazard - In no way weld in an with this space or close to hay, feed bags, gasoline, diesel, hydraulic fluids or something else that can be inside the reach of your welding sparks that would cause a fire or explosion. Not at all weld single handedly. Forever have a buddy close in case of an emergency.

Significance of Welding Machines and its Contributors

This can be very significant to check out the several types of equipment supplier that's out present. Most of them are centered on remarkable offers and more. It will get relevant to find the most useful types of welding machine supplies and much more.

All essential machines have to be targeted upon and that is very important to getting exciting offers. Wonderful provides are put forward and finest varieties of welding supplies be certain that people get amazing offers and more. This may be appeared into if someone needs to get welding equipment.

Welding equipment is associated for a complete lot of reasons. Mainly as a result of it becomes important to get wonderful offers which all clients have a tendency to like a lot. It's required to take a look at the various kinds of work this welding machine provides trust to achieve.

The profits of a Welding Career

Welding is an important skill because people's lives can depend on a metal construction to be strong and last for many years.

A certificate earned during a welding training list can prove to potential employers that they can count on you to possess the skills required to do high quality welds.

Here are a few machines you can function through hands-on experience:
• Electric Arc Welder
• Automatic Pipe Bevel
• Flux Core Arc Welders
• Hand-Operated Grinders

The welding preparation programs offer a range of certifications through professional schools in your area.

You can get the welding skills that are in demand by employers in as rapid as 40 weeks.
Attaining a high quality welding career will help guide to a very successful, and beneficial, career!

Features Found on Mig & Tig Welders

Mig Welding Equipment
Ranging in size from a small, convenient 115v, 20 amp machine to full sized shop automotive service equipment, mig welders are one of the few that unite a relatively low cost tag with high quality performance. You can also gain full control over the quality of the weld with a full variety of settings. Finally, these machines turn up with added benefits such as colder running temperatures and some of the best guarantee options.

Tig Welders
Even the most essential tig welding machines move toward loaded full of features. Press on button control panels create them easier to use while advanced end models let you easily adjust the machines repeatable weld cycles, start, and weld hollow. To modify the shape and size of the bead, look for models with true square wave AC output and pulse style. Finally, look for models with further safety features such as warning code circuitry and voltage protection.