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.

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.

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.

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.

Underwater Welding Work Process:

Underwater welding consists of more than a few methods used for repairing ships, pipelines and offshore oil platforms. Undersea welding splits into 2 major categories: wet and dry underwater welding. Both go down below hyperbaric welding, which is welding completed at augmented pressure, such as being undersea. Underwater welding used steel for repairs.

Dry undersea welding is completed by insertion a structure around the point to be welded. The structure is preserved approximately the weld point and gas fills the area shaped by this juncture. The welding then begins in the chamber. Dry undersea welding is careful to be very correct in its last product. Wet undersea welding uses water-resistant electrodes to provide power to the welding tools. Wet underwater welding is measured to be easier to start due to the lack of preparing the dry welding's chamber. Wet welding too allows for more liberty of movement by the welder.

Wet undersea welding has extra risks than dry undersea welding. One such danger to the welder is beginning electrocution. The equipment used must be insulated and power has to be correctly maintained. In adding to electrocution, welders have to be worried with diving issues and the probable build-up of oxygen and hydrogen gases, which know how to be explosive.

Welding Symbol Terms:

Reference Line: Is always drawn as a horizontal line.

Arrow: May be drawn from either end of the reference line. It always touches the line that represents the welded joint.

Tail: Used only when necessary. Used to give information on specifications.

Weld Symbol: Indicates the type of weld to be made.

Arrow Side: The side of the metal which the arrow touches.

Other Side: The opposite surface from the arrow.

Root Opening: The space between the pieces at the bottom or root of the joint.

Groove Angle: This is the included angle or total angle of a groove weld.

Contour Symbol: This is the shape or contour of the finished weld. Shown as a straight or curved line.

Finish Symbols: Indicates the method of finishing. C: Chipping G: Grinding M: Machining R: Rolling H: Hammering

Depth of Bevel, Size or Strength: The "S" position on the welding symbol indicates the depth of bevel or the depth of preparation for a groove type joint.

Groove Weld Size: Given in parentheses in the "E" position on the welding symbol indicates the depth to which the weld penetrates into the base metal.

Length of Weld: On intermittent welds, the length dimension is used to indicate the length of each weld.

Pitch of the Weld: This indicates the distance from the center of one weld segment to the center of the next.

Backing Weld Symbol: A backing weld may be used to obtain 100% penetration when welding is possible on both sides.

Melt-Through Symbols: The melt-through symbol is used on welds that are welded from one side only and require 100% penetration.

Weld-All-Around Symbol: This indicates that the same type of weld joint is used on all edges of a box or cylindrical part.

Field Weld Symbol: Used when the weld is to be made away from the shop.

Multiple Reference Lines: Used when a sequence of operations is to be done. The reference line nearest the arrow indicates the first operation. The last operation to be performed is on the reference line furthest from the arrow.

Welding Helmets

Metal fume concentrations inside the welding helmet and in the personal breathing zone in 23 experimental welding exposures were studied to explore whether welding helmets use substantially attenuates exposure to airborne metal fume. Observations produced a mean ratio of inside to outside metal fume concentrations of 0.9 +/- S.D. 0.2 with a highly variable effect. Iron fume concentration was inversely correlated with this ratio, representing greater helmet-associated attenuation with heavier exposure.

A study was conducted to compare the iron oxide fume concentrations inside and outside the helmets of welders. Airborne iron oxide fume concentrations were determined simultaneously at four body locations--the left front shoulder, right front shoulder, front chest, and inside the helmet--during welders' normal activity. Results indicate that the fume concentrations at the actual breathing zone inside helmets are reduced to 36%-71% of concentrations outside the helmets, depending on the type of welding and employees' postures.

View area: 90*40mm
Cartridge size: 350*220*180mm
UV Transmittance:0.00006%

* Always wear safety glasses or goggles under a welding helmet or faceshield to protect workers from particles.
* Also protect the eyes of the cutter’s or welder’s helper and bystanders with lenses designed to protect against cutting or welding light.
* Use the darkest shade of lens possible:
Torch soldering
Torch brazing/cutting
Gas welding
Electric arc welding
* Use ANSI Z136 eye protection for laser light hazards.

Solar powered;
View area:90*40mm
Shade no in dark state:9-13#
Response time:0.1ms

These data suggest that welding helmet use provides marginal and highly variable reductions in fume exposure and cannot substitute for standard respiratory protection.