Welcome to the welding shop section in our website. Actually, this section is dedicated for everything about welding. In here I will briefly explain you following topics,
What is welding?
Welding accessories and
Different types of welding
So, what is welding?
Welding is the joining of two pieces of metal together to form one piece by heating the metals to their melting points. During the heating process additional metal also added to help the bonding. A welding machine is used to create the heat and apply the filler metal.
There are three parts of the welding process the welding arc, the filler metal and shielding the weld.
First, let's learn about the welding arc. Welding machines create an electric arc
similar to a continuous spark that comes from the electric circuit created between the machine and the metal. This arc creates heat up to 6500 degrees Fahrenheit.
The next part of the welding process is filler metal. Filler metal adds additional metal needed to the welding joint to strengthen the weld.
There are two basic types of filler metals used in welding. They are bare wire and flux-cored wire also called tubular wire. Welding wire can vary in the type of metal it's made from and its thickness or diameter.
The final part of the welding process is shielding. The weld needs to be protected while it's in a molten state. Surrounding air can contaminate a weld causing it to weaken. Shielding gas covers the area where the filler metal melt. The weld sets up in fractions of a second so not much gas is needed.
Basically, you need a welding machine (we call it welding plant), welding wire and power supply. But there are many other types of equipment which will help to make your life easier and safer.
Getting a good welding cart will help you a lot. You will not need to roam around to collect the items you need. Welding cart is going to hold your welder, your gas bottle, and other accessories.
A great project for a beginner is to weld up your own cart from scratch. If not you can buy a new cart also.
Buying a welding cart – Complete guide
Another essential item that everybody need is a good steady workbench. Metal workbenches will help you to weld safely. Beginners can try to build their own workbench. It will be a good experience and you can design it with the available space in your place. When you are designing it try to add adjustable welding slot clamps, magnets, and angle clamps. You can see available welding table in the market and get some idea about features.back to menu ↑
Today most of the advertisements, social media give an impression that welding is so easy and risk-free. But it’s not true. It is a dangerous process and you must follow safety precautions. And no matter how good your skill level, you must have these items every time you fire.
The welding helmet is an essential item you need. The welding arc is harmful to your eyes. That’s why you must use welding helmet. Some people use to close their eyes while welding, but that will not going to save you. The risk is still there. There is a chance of hitting small particles of arc on your face or eyes.
Helmets also come with new features now. Now there are auto-dimming welding helmets, unlike traditional fixed-lens helmets. These masks can dim the lens in a fraction of a second. So, you can find your weld joint easily. You can also adjust the dimming time with an auto-dimming helmet. My advice is to try to get a quality auto-dimming welding helmet so you can spend more time improving your welding skills and stays safe while welding.
As I told before welding is the act of melting metal together and that creates a lot of heat. So, if you accidentally touch it, it will definitely burn your hand.
So be sure you pick up a pair of quality welding gloves so that you can protect
yourself from UV rays and the high heat.
There are different types of welding gloves that are designed for different types of welding. For instance, TIG welding gloves may be thinner and made of a different type of material to help with dexterity and feel.
MIG and arc welding gloves are progressively thicker and larger to protect from the Sparks and spatter that's produced by those types of welding.
Welding curtains are used for two purposes. For the safety of people who haven't involved the welding and if there is a fire risk. People who work near where a welding process is going on can affect by UV. So, these curtains come with UV and blue light filtering.
It’s better if you can have a welding jacket because of heat and harmful UV rays. Usually, it is both flames resistant and anti-static plus it's going to keep your favorite t-shirts from getting tiny pinholes.
It’s better if you can wear a safety glass whenever you are welding. Because it’s not only welding, sometimes you have to grind, cut, hammer and etc. So, I’m suggesting you wear it when you are doing it.
Try to buy safety glasses that are both flexible and low-profile so they can easily fit underneath of your welding helmet.
One of the most important tools that you can have around your shop is a good angle grinder. By changing the discs on the angle grinder you can perform a lot of different tasks when welding. It’s always good to use the angle grinder to smooth proud welds, clean the weld seam or cut metal.
I like to keep two of these angle grinders on hand. One with a flap disc and one with a cutting wheel to save time when working on a project unless you have a helper on hand at all times.
You will need welding clamps and magnets and they will allow you to set up your workpiece and keep your hands-free. They also help to hold your workpiece together as you weld up a long scene. There is number of different types of loading clamps and magnets available.
My favorites include the large locking C clamp pliers which are used to hold large workpieces. A smaller mini pinch weld clamps to hold intricate parts. The corner magnets to hold 60and 90-degree angles.
Welding corrosion is one of the major issues we are facing when welding. This is why skilled fabricators used to clean and protect their work area before and after the weld. To accomplish this you can use stainless steel brushes to clean the weld area before you weld.
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Different Types of Welding
Next, we'll learn about different types of welding. The type of welding is defined by how the filler metal is fed into the welding process. There are two types of welding wire, feed welding, and stick welding.
Feed welding uses a gun to feed the wire into the welding area. Two types of guns are used for wire feed welding. They are standard guns and spool guns. A standard gun uses a wire housed inside the machine and fed through a cable. A spool gun uses a wire housed on the gun itself. In wire feed welding where the gun trigger has pulled an arc is created at the tip of the gun between the wire and the metal to be joined. The wire melts to fill the joint and if you pull the more, it will release more wire into the welding area.
The type of wire determines the welding machine setup. When a solid wire is used shielding gas from a gas cylinder connected to the machine is needed to protect the weld this is also known as MIG welding. When the flux-cored wire is used a chemical inside the wire provides the shielding so no additional gas is needed. The other type of welding is called stick welding. Stick welding doesn't use a gun it uses a stick electrode placed in an electrode holder. The arc is created between the stick electrode and the electrode melts as it's fed into the weld area. No additional shielding gas is used when stick welding. Because the stick electrodes are coated with chemicals that are released when melted to create the shield.
MIG stands for Metal Inert Gas welding, also known as wire feed welding.
The term MIG is technically incorrect, but everybody still uses it. MIG welding is a very familiar term but the American Welding Society has designated this as the gas metal arc welding process to include all types of solid wire and shielding gases. Now wire feed welding does have the reputation for being really easy. It might be a little more accurate to say that it's easy to get started in any type of electric arc welding. The distance at the arc travels between the electrode and the metal called the arc gap is extremely important with wire feed. When the voltage and wire speed are set correctly the welding machine automatically maintains a constant arc gap even with slight variations in the position of the wire feed.
TIG welding stands for Tungsten Inert Gas Welding, also known as “Heliarc” welding. Actually, tungsten has a very high melting point. So, here electrode gets hot but it doesn’t melt. You need to have a good TIG torch and this particular TIG torch I want you to hold the torch like a pencil. The reason for that is you're going to be manipulating, you're going to be turning and twisting and getting to all kinds of tight places.
Electron Beam Welding
Both electron beam and laser welding methods utilize a concentrated beam of energy that can be precisely controlled in both energy and location. Thus the technologies are ideal for precision welding. EB welding is an accelerated beam of electrons that can be magnetically deflected and focused on the workpiece.
The biggest advantage of EB welding is it can deliver deeper penetration weld than any other process and EB weld can be up to two inches deep in steel with a width of fewer than 0.2 inches the narrow width also called the heat affected zone. It means minimal heat going into the part as well as minimal distortion. EB can also apply very light welds only a few thousandths of an inch deep. To generate electrons, EB welding must take place in a vacuum.
Laser welding uses amplified light that is delivered and deflected by glass lenses mirrors and often a fiber-optic cable.
Laser Welding can do in open air so no vacuum chamber required like EB welding. Robotic control lasers are used to achieve decent weld penetration up to about a quarter of an inch in steel and also has a small heat affected zone. But a laser simply can't achieve the same penetration as an electron beam one of the reasons for this is the molten material in the weld pool can act like a mirror and reflect laser energy away from the piece.
So, hope you know everything about welding shop. I hope you got a detailed guide on that. Feel free to give your opinions or comments. Thank you!