14 May

10 Mistakes in Running a Welding Operation and How to Fix Them

With so many factors to monitor — equipment, weld procedures, filler metals and MIG gun consumables — it’s inevitable that mistakes will occur in most welding operations on any given day. Human error dictates that a welding operator can easily set a power source and wire feeder to the wrong parameters or trim and install a MIG gun liner improperly. But there are other mistakes that can occur in welding operations on a regular basis — ones that many companies may not even realize that they are making.

The reality is, however, that these mistakes can have a significant impact on quality, productivity and a company’s bottom line. Fortunately, they don’t have to happen. Consider these top 10 mistakes involved in running a welding operation, along with some recommendations for solving them.

Mistake No. 1: Improper Filler Metal Storage and Handling

Storing filler metals in an area where they are prone to accumulating moisture or exposed to other contaminants (e.g., dirt, oil or grease) can have an adverse effect on their welding performance. To prevent damage, companies should store filler metals in a dry, clean area with a relatively constant temperature until they are ready for use. Spools and coils of wire that are kept on the wire feeder for an extended period should be covered securely with a plastic bag or removed from the wire feeder and stored in the original packaging. An enclosed wire feeder can also protect against contaminants. Such precautions prevent damage that can lead to poor weld quality, and ultimately, rework.

Mistake No. 2: Repurposing Old Equipment

It is important for companies to use the best equipment for the job. Repurposing old or dilapidated power sources, welder/generators or wire feeders can cause quality issues, not to mention downtime and additional costs for troubleshooting problems that inevitably arise from using dated equipment and technology. Instead, companies should consider the newer technologies available in the marketplace, recognizing the advantages these can offer in terms of improving weld quality and productivity. In most cases, newer equipment can provide companies with a quick return on investment and greater long-term savings – in a relatively short payback period.

Newer technologies often offer benefits like improved power efficiency, better deposition rates, lower weld prep time and faster training, all of which ultimately add up to greater arc-on time and productivity. Performing a thorough cost-savings analysis before buying new equipment can help companies assess their potential return on investment, as well as justify the capital expenditure.

Mistake No. 3: Using the Wrong Size MIG Gun

Using a too-low or too-high amperage MIG gun can lead to unnecessary costs for purchasing and replacing this equipment. Welding operators rarely spend the entire day welding or welding continuously, as there is downtime for part preparation, movement and/or fixturing. For that reason, it may be possible to use a lower amperage MIG gun or one with a lesser duty cycle on some applications. For example, using a lighter and smaller 300-amp MIG gun instead of a 400-amp model can provide welding operators with greater maneuverability and reduce downtime for fatigue. Lower amperage MIG guns tend to cost less, as well.

Conversely, on higher amperage applications and/or those that require longer periods of welding, it is important to use a higher amperage gun. Skimping and purchasing a lower amperage MIG gun in this situation can lead to overheating, premature failure and greater long-term costs. Companies should consult with a trusted welding distributor for MIG gun recommendations for their application.

Mistake No. 4: Improper Preheat or Interpass Temperature Control

It is not uncommon for companies to preheat too little or skip this portion of the
weld procedure altogether. Yet preheating is one of the biggest deterrents against cracking, as it slows down the cooling rate after welding. The type and thickness of the material being welded will determine preheat and interpass temperature. These requirements can be found in the application’s welding procedure, welding codes or other fabrication documents. For the best results, welding operators need to preheat the material completely through and extend the heated area to approximately three inches on either side of the weld joint. Welding should commence while the material is at or above the preheat temperature. Allowing the weldment to cool below the required interpass temperature may also lead to cracking.

Mistake No. 5: Ignoring Preventive Maintenance

Preventive maintenance (PM) is a frequently overlooked part of the welding operation, but it is critical to preventing unscheduled downtime and keeping repair costs low. A well-performed PM program can also help increase productivity, extend equipment life and create a workplace philosophy that encourages shared responsibility for, and interest in, preserving the integrity of the welding equipment. Companies should develop a regular timetable to inspect their power sources, wire feeders and MIG gun or TIG torches during scheduled downtime in production. Between welding shifts is often enough time to perform routine inspections. Checking consumables regularly for spatter build-up — and replacing these components as needed — is also an important part of a viable PM program.

How to TIG Weld Stainless Steel Effectively: Preventing Carbide Precipitation

Mistake No. 6: Shielding Gas Inconsistencies

Using the correct type and/or mixture of shielding gas can help companies prevent weld defects, minimize excessive spatter and reduce costs for rework or post-weld cleanup. Shielding gases also determine arc characteristics and weld penetration on a given application. Straight CO2 provides good weld penetration, but it is prone to spatter and has a less stable arc than mixtures that include argon.

High argon mixtures (a minimum of 85 percent argon for solid wire or as low as 75 percent for metal-cored wires) are the best choice. These mixtures can be used in the spray transfer process to promote higher deposition rates and generate less spatter. For TIG welding, the appropriate argon/helium mixture can improve speed, quality and arc characteristics. For both MIG and TIG welding operations, companies should purchase their shielding gas from a reputable welding distributor and be certain that it meets the purity requirements for their application. All gas delivery systems should be free of contaminants that could enter the weld puddle and welding operators should use the correct shielding gas flow rate. Too little gas flow won’t properly shield the molten weld pool, while too much flow can cause turbulence and aspirate air into the weld puddle. Protecting the weld puddle from drafts is also critical.

Mistake No. 7: Purchasing Filler Metals Based on Cost Only

Due to the initial up-front cost savings, the temptation may be great for companies to purchase less expensive filler metals. However, doing so can often lead to greater long-term costs and lower productivity levels. It is not uncommon, for example, to experience downtime associated with poor wire feeding, excessive spatter or, potentially, weld defects when using lower quality filler metals. Companies may also find themselves experiencing an excessive amount of time for non-value-added activities (those that do not directly contribute to their throughput), such as applying anti-spatter and post-weld grinding or rework. For that reason, it is important to look at the total cost of using particular filler metals, as opposed to the per-unit cost. If more expensive, higher quality filler metals can minimize labor costs for non-value-added activities and provide better weld quality and/or greater productivity, then the higher up-front cost makes good sense in the long run.

Mistake No. 8: Improper Weld Preparation

Skipping steps in weld preparation can lead to weld defects, rework or scrapped parts. Welding operators should always take care to clean the base material before welding to prevent contaminants like dirt, oil or grease from entering the weld puddle. Similarly, monitoring part fit-up is a critical part of the pre-weld process. Welding operators should carefully assess the weld joints to ensure there are no excessive gaps, as poor part fit-up can lead to issues like burn-through or distortion on all materials, but particularly when welding on materials like aluminum or stainless steel. Clamping or fixturing a part in the correct position is also a good practice to help protect materials like stainless steel against distortion or buckling.

Mistake No. 9: Disregarding MIG Gun Consumables

It is not uncommon for companies to overlook the importance of their MIG gun consumables. Unfortunately, that oversight can lead to a host of problems, including unscheduled downtime for changeover and/or rework of weld defects caused by a poorly performing contact tip, nozzle or liner. To help avoid problems, select consumables with a tapered design that locks conductive parts together to reduce heat buildup. Contact tips with coarse threads are a good way to speed up replacement and make sure installation is accurate. Look for consumables where the diffuser locks and aligns the liner with the contact tip and power pin for flawless wire feeding. These systems also offer error-proof liner installation with no measuring required; the liner is simply locked in and trimmed flush with the power pin at the back of the gun.

Mistake No. 10: Overlooking Training Opportunities

As with other parts of the welding operation, investing time and money in training can yield significant long-term benefits for companies. Not only do welding operators benefit individually from process and equipment training, but in many cases it can also help them optimize the welding operation for greater efficiency. Too, proper training can give companies a competitive edge over those who have less-skilled labor and it promotes greater teamwork among employees. Typically, training opportunities are available through equipment and filler metal manufacturers or through welding distributors. In some cases, working with a local technical college can lead to training for specific applications and markets, allowing companies to bring in welding operators who are already trained for a given application and better promote their position in a given industry.

Making mistakes is human nature, but with some careful consideration, it is easy to avoid some of the more common ones associated with running a welding operation. Measuring out long-term savings, versus cutting costs up front, is a particularly good way to avoid pitfalls that could lead to excessive downtime, quality issues or lost productivity. And it can have an excellent impact on a company’s bottom line.

powerwelds Welding Tips

14 May

Troubleshooting Common Industrial MIG Welding Problems

Like any welding process, MIG welding has its complications. Even so, there is no reason to let common problems slow you down. With a bit of knowledge and some solid troubleshooting skills, you can easily find the right solution to get back to welding—sooner than later. Consider the following guidelines to help you along the way.

Keep Covered

Getting Started with Welding: A Welding Guide for Beginner’s — MIG welding defects can cause downtime and lost productivity due to rework. Use these tips to help you minimize these costs by quickly identifying and resolving MIG welding problems.

Porosity occurs when a gas pocket becomes caught in the weld metal. This discontinuity can appear at any specific point on the weld or along its full length, and/or on the surface or the inside of a weld. The result, regardless of the location, is always the same: a weaker weld.

Inadequate shielding gas coverage is one of the most common causes of porosity. To correct this problem, first check the regulator or flow meter for adequate gas flow, increasing it if necessary, and check the gas hoses and the gun for leaks. Whether welding inside or outside, shield the arc and weld puddle from drafts with a welding screen.

Next, confirm that the MIG gun nozzle is large enough for the application, as too small of a nozzle can prevent proper shielding gas flow. Keep the nozzle one-fourth to one-half inch away from the work piece, make certain it is free of spatter, and always use the correct contact tip recess. Slow your travel speed and hold the MIG gun near the bead at the end of the weld until the molten metal solidifies; pulling the gun away too soon can interrupt gas coverage and leave the setting weld vulnerable to the atmosphere.

Additional causes of porosity include: using the wrong gas (always use a welding-grade shielding gas appropriate for the base metal and filler metal), using too much or the wrong type of anti-spatter (use the correct amount and type for your application) and extending the welding wire too far out of the nozzle (extend no more than one-half inch beyond the nozzle).

Impurities in the base metal, such as sulfur and phosphorous in steel, or a dirty base metal can be further causes of porosity. If specifications allow, consider changing to a different composition of base metal, and always remove rust, grease, paint, coatings, oil, moisture and dirt prior to welding. Filler metals with added deoxidizers can help to “clean” the weld, but should never be solely relied upon to minimize porosity. Finally, replace any wet or contaminated shielding cylinders immediately.

Don’t Be Undercut

Undercutting occurs when a groove melts into the base metal next to the toe of the weld and the weld metal fails to fill that area. This discontinuity weakens the toe of the weld, increasing the chances of cracking. Correcting the problem is relatively simple: reduce the welding current, decrease the welding arc voltage and adjust your MIG gun angle toward the joint. Reduce your travel speed so the weld metal completely fills the melted-out areas of the base metal. When using a weaving technique, pause slightly at each side of the weld bead.

When the weld metal fails to completely fuse the weld metal with the base metal or with the preceding weld bead in multi-pass applications, incomplete fusion can occur. Some people refer to this problem as lack of fusion. Generally, an incorrect MIG gun angle is the cause and you should adjust it accordingly. Follow these steps:

Place the stringer bead near the proper point on the joint, adjusting the work angle or widening the groove as needed to access it fully.
Keep the arc on the leading edge of the welding puddle by maintaining an angle of zero to 15 degrees.
When using a weaving technique, momentarily hold the arc on the groove sidewall.

If correcting the MIG gun angle does not remedy incomplete fusion, look to see if the welding puddle is too far ahead of the wire. If so, increase your travel speed and/or the welding current to correct the problem. Conversely, if you suspect insufficient heat input has caused incomplete fusion, select a higher voltage range and/or adjust the wire feed speed as necessary. Finally, always clean the surface of the base metal prior to welding to remove contaminants that may prevent the metal from fusing together.

Another common MIG welding problem—spatter—occurs when the weld puddle expels molten metal and scatters it along the weld bead; this molten metal then cools and forms a solid mass on the workpiece. Excessive spatter not only creates a poor weld appearance, but it can also lead to incomplete fusion in multiple welding pass applications. Too fast of a wire feed speed, too high of a voltage setting, and too long of a welding wire extension, or stick-out, can cause spatter. Lowering the given settings and using a shorter stick-out can help.

Like porosity, insufficient shielding gas and/or dirty base materials can cause spatter. As necessary, increase the shielding gas flow at the regulator and minimize drafts near the welding arc, clean and dry the welding wire, and remove all grease, dirt and other contaminants from the base metal.

Other factors that can cause spatter are: the wrong size contact tip, a worn contact tip or the wrong tip to nozzle recess. Be certain you have the right contact tips, nozzles and recess parameters for the application.

Keep Track of the Heat

Excessive penetration occurs when the weld metal melts through the base metal and hangs underneath the weld. Excessive heat input is usually to blame for the problem. To correct this, select a lower voltage range, reduce the wire feed speed and increase your travel speed.

Conversely, insufficient heat input can cause lack of penetration, or the shallow fusion between the weld metal and the base metal. Selecting higher wire feed speed, a higher voltage range and/or reducing travel speed are all viable remedies. Preparing the joint correctly also helps prevent lack of penetration—the preparation and design should permit access to the bottom of the groove and allow you to maintain proper stick-out and arc characteristics.

All About Wire

Wire feed stoppages and wire feed system malfunctions can adversely affect the welding arc and create irregularities that may weaken the weld bead. Birdnesting, a tangle of wire that halts the wire from being fed, is a common problem. You can resolve birdnesting by flipping up the drive roll and pulling the wire back out of the gun. Next, trim the affected wire and re-thread it through the feeder and back to the gun. If the welding specifications allow, decrease the drive roll tension, use a larger diameter wire and/or reduce the distance the wire feeds (use shorter cables) to minimize the chance of birdnesting.

Burnback is also very common. It results when a weld forms in the contact tip, and usually occurs because of too slow of wire feed speeds and/or from holding the MIG gun too close to the base metal during welding. To correct burnback, increase the wire feed speed and lengthen the distance of the MIG gun from the workpiece (the nozzle should be no further than one-half inch from the metal). Replace burnback-damaged contact tips by removing the nozzle and the contact tip (which may be melted to the wire), snipping the wire, installing the new contact tip and replacing the nozzle with one that has the appropriate tip recess for the application.

Other causes of wire feeding problems include liner blockages, improperly trimmed liners (too short/burred/pinched) or the wrong size liner. To remedy these problems, replace any liner if you find a blockage, always trim the liner according to the manufacturer’s direction and be certain you are using the correct size liner for the welding wire diameter.

No Cure-All

Remember, quality MIG welds are the result of not only good welding technique, but also your ability to identify and solve problems quickly if they do occur. Continue arming yourself with some basic information and you’ll be able to tackle the most common problems associated with MIG welding without sacrificing time or quality.

powerwelds Welding Tips

14 May

Manual Metal Arc Welding: Why every weld matters

Every day we cross bridges, hold on to stair railings, lean over balustrades, and rely on the same thing when doing so: support and safety. These properties can only be achieved through flawless, high-quality weld seams produced by qualified manual metal arc welders. We are talking about a professional field in which there is a huge shortage of skilled workers—a problem that is causing concern in the entire industry. But what is actually important when it comes to manual metal arc welding? What can happen in the event of weld defects? And why will this profession always exist despite advancing automation?

“Welder urgently needed” ads are proliferating more than ever before. The shortage of skilled workers has the welding industry firmly in its grip. As ever more members of the older generation retire and take their considerable amount of valuable experience with them, there is a lack of younger welders coming through the ranks to replace them. Manual metal arc welding, which requires skill, expertise, and the highest sense of responsibility on the part of every welder, is particularly affected. If bottlenecks occur here, companies are no longer able to fulfill their orders—especially where automation as a solution is not an option. Firstly, let’s take a look at what the field entails and in which industries manual metal arc welding has become particularly established.

What is Manual Metal Arc Welding and what does it involve?

Manual metal arc welding is a manual joining process that permanently bonds metals together. It includes processes such as MIG/MAG Welding, TIG Welding, and Electrode Welding, and is indispensable in many sectors. Manual metal arc welding is versatile, usually requires little equipment, and impresses with a high degree of mobility. As a result, it has become firmly established in steel construction in particular, but manual metal arc welders are also used on a daily basis for repair welding, pipeline construction, assembly work, or on construction sites.

Automation as a solution for everything (or not)?

Where there is a lack of people, robots will step into the breach—or so you might think. This is indeed the case in many fields, including the welding industry to some extent. Solutions robots mitigate the shortage of skilled workers, allow companies to breathe a sigh of relief, and reduce the strain on workers, especially when it comes to repetitive and tiring work. However, automated processes are reaching their limits when it comes to manual welding, because not every welding task is suitable for robots. Manual welding is advantageous or, in many cases, indispensable, especially with small production runs and for highly specific or complex components.

Manual metal arc welding is also the benchmark where highly individual and flexible welding is required, for example for vehicle repairs or when welding at great heights:

In certain situations and at certain locations, you can only weld by hand. A good example is the construction of highway bridges. Finished sections of roadway are produced elsewhere and delivered to the site, but when the bridge is finally erected, the individual sections are joined together by manual welders. There is also no automated process here, so the responsibility ultimately lies with the individual welding specialists. That is why it is so important not only to continue to have enough manual welders, but above all to have highly qualified ones.

Requirements of Manual metal arc welding
But what makes a good welding specialist? What I need to bring to the table if I want to work in this profession? The fundamentals are the trio of manual dexterity, understanding materials, and resilience. Be it lying under a pipe or kneeling in a narrow container, the working environment is often harsh and hours of welding under difficult conditions can be very physically demanding. Awareness of how you can protect your own health is a fundamental prerequisite for every manual welder: “As a manual welder, you have to pay special attention to your own safety. You are often working for a long time in the most adverse conditions or in the narrowest of spaces, for example in a tank. It is important to ensure proper ventilation and always have a responsible supervisor at your side who checks the safety measures during the welding process.”

Excellent knowledge of materials also plays a key role. “I need to know how heat input and distortion behave during welding, for example, and the joint preparation work must also be carried out properly. What you weld has to last—you have to be able to rely on it”. But how can you be certain about the quality or qualifications of the specialists employed? Welding tests are essential to ensure that the welders are highly trained specialists and that their work is performed properly and professionally. “With their knowledge and experience, manual welders bear an enormous responsibility that cannot be emphasized enough,” emphasizes the welding technology expert.

The highest sense of responsibility for every seam

Where there is a high level of responsibility, mistakes are usually fatal. This also applies to manual welding, because weld defects can have serious consequences. A weld that is not executed properly could crack at some point and lead to material breakage—or, in the worst case, also endanger the safety of people.

I know of a case that happened on a construction site in France a few years ago. A formwork panel fell from a higher floor, directly onto the head of a welder working there. The panel punctured his protective helmet and practically drilled into his head. He was in the intensive care unit for months, fighting for his life. He won the battle, but still lives with a piece of plastic in his head that replaces the part of the skull that was damaged. The cause of this accident was a defective weld, drawing attention to the high level of responsibility as a welding specialist has to bear.

MIG-315L PRO MIG welder and MIG-500PW MIG welder: Effortless manual welding

In addition to skill, sophisticated knowledge of materials, and the highest sense of responsibility, the optimum welding machine is also an important ingredient for successful manual welding. The question here is, what does a good manual welding machine need to be able to do? First and foremost, it must be perfectly matched to the welding task at hand. For example, if welds have to meet the highest standards in terms of both quality and appearance, the MIG-500PW MIG welder is an ideal choice. Visible seams on stainless steel handrails or high-quality pipe connections for swimming pools, as well as precise applications in tank and industrial plant construction, are produced by the MIG-500PW mig mag welding machine with ease.

The MIG-315L PRO MIG welder is a reliable companion when welding has to be carried out under the most adverse conditions. On the outside, the durable machine keeps environmental factors like dust and moisture at bay, while the pioneering technology offers a range of convenient functions to facilitate the welding process. At just 22 kg, the Ignis is lightweight, but still very robust. Welders can therefore count on the powerful manual welding machine both indoors and outdoors, in rain or sunshine, at great heights, or in the tightest of spaces.

Be it MIG-315L PRO, MIG-500PW, or another high-quality welding machine, the key is to choose a machine that is perfectly designed to meet the needs of both welders and the task at hand—and on which the specialists can rely on day in, day out. But no matter the manual welding task, the responsibility does not lie with the machine, but rather in the hands of each and every individual welding specialist. After all, despite all the technical progress and automation we have seen, it is people who remain indispensable in many places.

powerwelds Welding Tips

9 May

Most Common Types of Welding Machines

Did you know that welding has been around for centuries? What about the types of welding machines? Dating back to the Bronze and Iron Ages, welding has become a part of our lives that it’s stated that more than half of the products made by man require welding. This means the planes, trains, automobiles, bridges, and even computers all have to go through a welding process before being completed. That is interesting, right?

However, it was not until the 19^th century specifically 1881 that true welding was invented. As time has gone by, welding has become an exciting profession that is enabling welders to not only sustain themselves but also earn six-figure incomes.

However, before you get too excited, you need to master the art of welding by knowing the following:

Basic welding,
Types of the welding process
The different types of welding machines.

But wait a minute, today we are not going to look at the first and second art of welding but we are going to share with you the 4 popular types of welding machines in the welding market.

Different Types of Welding Machines

There are many types of welding machines that come in different sizes and shapes. For example, when it comes to size, the large-sized welding machines are mostly used in the factory while the small size ones are for domestic purposes. The good news is that we are going to look at different welding machines found in the market that makes welding easy.

MIG Welding Machines

MIG welding machines are one of the best machines to use for different places such as homes, workshops, and industries. Also known as Gas Metal Arc Welding Machines, these machines can weld various metals like aluminum, nickel alloys, mild steel, magnesium, and stainless steel.

Mostly used in automotive industries to repair cars, motorbikes, SUV’s and Vans, the machines are also used in the construction sectors that use steel such as homes, office buildings, bridges among other places. Last but not least, these machines are used in High Production Manufacturing to create auto parts, computer components, and ship parts as well as other items.

However, there are different types of MIG welding machines worth mentioning. These usually include:

Gas-less MIG Welding Machines: It is common to find these Gas-less Welders on job sides and also homes especially by people who work outside. The best part of it is that the users don’t worry about the wind blowing the shielding gas aside and creating any disturbance during the welding process.
Wire Welding Machines: Also known as flux core welders, the Wire Machines are used on thin or thick plate metals.

TIG Welding Machines

Another great welding machine is Tungsten Inert Gas (TIG) which is used in different metals. These mainly include gold, copper, brass, aluminum, nickel alloys, magnesium, titanium, and stainless steel. Ideal for making different items, the machine is also best at repairing damaged parts at homes and indoors industries, unlike outdoor sites or fields.

That means when it comes to welding using TIG Machine, the amount of heat created depends on arc polarity, amperage, and arc voltage. Polarity outlines the direction of the current flow in DC welding. Known to use foot-operated variable amperage these machines also have other numerous controls. For instance, if you are welding aluminum, one of the vital controls to consider is the balance that maintains the cleaning versus penetration levels on aluminum.

Apart from the foot paddle, other TIG Machine parts also include an electric torch, a filler metal rod, among other parts. Note that, the TIG Machines are used in power constructions, machinery, petrochemical industry, ship constructions as well as indoor and outdoor decoration constructions, and so on. With that in mind, you should know there are several types of TIG Welding Machines used to weld metals. These mostly include:

AC. TIG Welding Machine: Known to be smaller in size and light in weight. An AC TIG Welder is mostly used to weld aluminum because the material is surrounded by an oxide layer. So, for the chance to destroy the oxide for the aluminum itself to melt, an A.C TIG Welding Machine is used.
DC. TIG Welding Machine: Suitable for welding all types of metals, the D.C. welding machine can be used in all sorts of work.

Plastic Welding Machines

Just as the name suggests Plastic Welding Machines are used to weld different kinds of plastic materials. Yes, you heard me right. Plastic parts are usually used in many industries such as automotive, medical, and electronic applications that make toys, household utensils, and also heart valves among others. There are two types of plastic that are thermosets and thermoplastics. However, only thermoplastics materials are suitable for welding.

This means the thermoplastics are joined together by melting the surfaces and pressing them using a plastic welding machine. Keep this in mind; there are different types of plastic welding machines such as:

Hot Air Plastic Welding Machines: These kinds of machines are used to weld any chemistry comparable types of plastics. That means they can be used in producing large chemical tanks, heat exchangers as well as plumber fixtures.
Laser Plastic Welding Machines: They are used when you are concentrating a beam of light on a particular spot so that the area under the laser beam absorbs the light and becomes highly energetic.
Ultrasonic Plastic Welding Machines: Also used in metals, the Ultrasonic machine is used to converts electricity to mechanical vibrations thus paving way for molecular bonding in plastics as well as metals.
Spin Plastic Welding Machines: Designed to apply force while rotating one part of plastic against its stationary mate, Spin Plastic Welders is used in different industries that use friction welding techniques for the thermoplastic material. These industries are automotive and domestic appliance industries where they use the Spin machine to make aerosol bottles, polyethylene floats, PVC pipes, and fittings as well as transmission shafts.

Spot Welding Machines

Used for joining parts that are normally up to 3 mm in thickness, Spot Welding Machines are mostly used in several industries. These mostly include automotive, electronics, constructions, aerospace, metal furniture, medical buildings, rail, among others. Note these machines are mostly used to weld more than two metal sheets.

Nonetheless, there are other metals except for steel that the Spot Welding Machines can be used upon which are Bronze, Phosphor, Brass, Titanium, among others. Known to be available in permanent plus transportable forms of a machine, there are several kinds of Spot Welding Machines for different purposes. These include:

Seam Spot Welding Machines: These kinds of machines are usually used to make gas-fluid tight joints in a variety of sheet metal fabrications. For example, it is used in making steel fuel tanks for motor vehicles, steel drums, tin cans, and domestic radiators.
Press Spot Welding Machines: Mostly used through the metalworking sectors, the Press Spot Welding Machines is suitable for fasteners and studs as well as welding tight spots spaces.
Bench Spot Welding Machines: Ideal for joining of wire ends, Bench Spot Welding Machines is widely used in automobiles, constructions, engineering among other industries.

Conclusion

I believe you agree with me that welding is an interesting profession. However, you don’t need to be a welder to be able to purchase a welding machine. As we have learned from the above information, you can choose the right welding machine for home purposes too.

All you need is to know which type of metals or plastic you are using, find the right features, know the price of the machine and you are good to go. Nevertheless, before we go, are you familiar with the above types of welding machines, and what do you think is best for you?

powerwelds Welding Tips No Comments

7 May

MIG Welding vs. MAG Welding – Is There a Difference?

Both MIG and MAG welding fall under the common name “gas metal arc welding” or GMAW.

However, MIG (metal inert gas welding) and MAG (metal active gas welding) have one significant difference — the type of used shielding gas.

In this article, we’ll examine the difference between the MIG and MAG welding processes and explain what each is meant for.

Getting Started with Welding: A Welding Guide for Beginner’s

How GMAW Works in Short

Gas metal arc welding (both MIG and MAG) joins metal by using a consumable electrode (solid wire) under the protection of a shielding gas.

The solid metal wire is pushed via an automated wire feeder through the MIG gun and energized via a power source. Small, portable, inverter-based MIG welders usually combine a wire feeder and a power source into one unit — the MIG welding machine.

For example, our MIG-200DP mig welder supports the MIG welding process because it has a wire feeder inside the unit, and an inverter-based power source that provides the necessary voltage and welding power in the wire.

200A MIG-200 4-in-1 Multi-Process MIG Welders

GMAW works by short-circuiting electricity released from the welding machine. The ground clamp is attached to the positive terminal, while the MIG gun is negative. So, once you grip the welded material with the ground clamp and the positive wire (coming from the MIG gun) touches the metal, the electrical short occurs, melting the wire and a piece of the welding joint. Metal melts due to internal resistance to the flow of electrons in the circuit.

gas metal arc welding

As the wire melts away, it deposits a metal droplet into the joint. Then, the wire feeder pushes more wire to short with the metal, and this process keeps repeating many times per second. This gives GMAW its characteristic sizzling sound and causes the spatter. Every time the wire shorts with the grounded metal, the sparks and spatter fly around because shorting works like a small explosion.

This is why the most common GMAW metal transfer method is called “short circuit metal transfer.” There are also other GMAW transfer methods like spray, globular, and pulse transfer. But, these are more advanced and out of this article scope. You can read about Pulsed MIG welding here if you want to learn more.

MIG – Metal Inert Gas Welding Process

MIG welding uses inert welding gas to shield the weld puddle from atmospheric contamination. Inert gasses like argon and helium don’t chemically interact with the molten metal, so they don’t influence the weld to a large extent.

You need to use 100% argon to weld non ferrous materials like aluminum, magnesium, copper, and nickel or its alloys. But, you cannot use 100% argon gas to weld ferrous metals like steel. We’ll talk about this soon when we get to the MAG welding.

MIG Welding vs. MAG Welding - Is There a Difference

MIG Welding vs. MAG Welding – Is There a Difference

Argon gas produces a favorable atmosphere in the weld puddle that’s very easy to ionize, so keeping a long arc with lower voltage is relatively easy.

Helium can be added to argon to increase arc heat, puddle fluidity, and weld penetration. You can also use 100% helium if welding very thick sections of aluminum or magnesium, but this will reduce arc stability.

MAG – Metal Active Gas Welding Process

MAG welding uses active gas or a combination of active and inert gasses. Active or reactive gasses directly influence the weld penetration, puddle fluidity, arc stability, weld spatter, and the resulting bead.

The two most commonly used reactive shielding gasses for MAG welding are oxygen (“O2”) and carbon dioxide (“CO2”). Oxygen is only used as an addition to argon, while it’s possible to weld with 100% CO2.

Custom gas mix

You cannot efficiently weld steel with 100% argon because the uneven iron oxides on the steel surface emit electrons that attract the arc in unpredictable directions. As a result, the weld deposits are irregular, and it becomes challenging to create a uniform weld.

Mixing oxygen with argon creates a reaction on the steel surface that results in a uniform iron oxide surface. This provides a stable path for the arc to follow and allows you to lay beautiful welds.

However, it’s rare for regular folks to use oxygen and argon bland. Carbon dioxide provides an excellent substitute for oxygen.

You’ve probably heard about an argon and carbon dioxide blend numerous times because 75% argon and 25% CO2 is the most common shielding gas employed in GMAW.

Adding carbon dioxide to argon creates a more favorable weld bead and a deeper penetration. Plus, the arc is more stable if using argon/CO2 than argon/O2.

However, you should use a MIG welding wire that contains deoxidizers to prevent reactive gasses like oxygen and carbon dioxide from causing porosity.

Speaking of which, MAG welding with a pure CO2 gas produces very deep weld penetration, but it does cause more spatter and produces slightly less appealing welds compared to the 75/25 mixture discussed earlier. If you have enough skills to weld with a very short arc, you can mitigate the increased spatter. Just make sure you use a wire designed for welding with 100% CO2.

Conclusion

While most people use MAG welding more often than MIG welding, almost everyone calls both processes MIG welding. While this is technically incorrect, it has become somewhat of a norm in the industry to refer to all GMAW processes as MIG welding.

This causes little to no harm in everyday welding work. So, most people just stick to MIG welding as their go-to name for the process. Since there isn’t a significant apparent difference, and most professionals know exactly which shielding gas to use with every metal, using the MIG welding term for both MIG and MAG is deemed acceptable.

It’s not like a certified welder would use straight argon to weld steel if someone would ask them to MIG weld it. Instead, they’d know to use either straight carbon dioxide or a mixture with argon, which is technically MAG welding.

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7 May

What are the benefits of TIG AC/DC welding?

While TIG is typically only used on very thin metals, it has a wide range of applications for both hobbyists and professionals. AC/DC welders are ideal for multiple uses around the home such as pipework, joint work, and automotive repairs, making it an essential piece of kit for DIY enthusiasts.

Delivering reliable and consistent performance, an AC/DC welder is a versatile machine for both hobbyists and professionals alike. An AC/DC welder gives you flexibility overall power and time controls while the option to use an alternating or direct current means you can better work with a wider range of metals and thicknesses.

Features of AC/DC TIG welders include variable current settings, upflow / downflow, foot pedal, and an array of time controls – plus all the different consumables and accessories you can use too. All of these features in one welding machine gives you much more versatility in the types of welds you can create and the metals you can work on. There are few welding machines more flexible than AC/DC welders.

What metals can I weld with an AC/DC TIG welder?

An AC/DC TIG welder can be used to create high-quality welds with aluminum, stainless steel, carbon steel, copper, titanium, nickel alloy, and more.

Being able to choose between alternating and direct current gives you convenience and flexibility in one machine. Alternating currents achieve greater penetration and is a good choice for thinner, more delicate pieces. A direct current creates an intense arc that is capable of melting harder metals like steel and titanium.

TIG is one of the most versatile and high-quality welding processes and being able to master it opens up a whole world of potential.

AC Polarity Qutout DC Polarity Output

Where is aluminum welding used?

It may be more challenging to master, but aluminum welding is well worth learning if you want to pursue a welding career. Being an alloy, aluminum is combined with a range of different metals like silicon, magnesium, and zinc, to produce different mechanical properties. These are each indicated by a numerical code like 3xx, 4xx, 7xx, and so on.

In the real world, this means aluminum welding is used in aerospace, infrastructure, and the marine, industrial, automotive, construction industries. It is part of the fabric of our civilization. Learning to weld aluminum opens up an entire world of career possibilities.

Non-touch Ignition HF TIG Welding

How to TIG weld aluminum

Aluminum alloy poses quite a few challenges. It disperses heat quickly, which can lead to distortion in the workpiece if you hold the torch still for too long. It’s also prone to ‘blow through’ where the metal simply melts away under a too-powerful arc. Oxidization – where the surface layer of the aluminum melts into the weld pool – can also be an issue if the heat isn’t set correctly.

Achieving this balance, as well as controlling the foot pedal, electrode, and filler rod is why aluminum has earned its tricky reputation.

Before even beginning to weld aluminum, you need to make sure it is thoroughly clean. Any contamination can cause oxidation so give the workpiece a good scrub with a wire brush and de-grease it if necessary.

TIG weld aluminum

An alternating current (AC) is better suited for delicate metals like aluminum as the heat is less intense. It can leave the finish looking a little rough though – yet another reason why aluminum is famous for being tricky.

A high frequency (contactless) start is best. In the vast majority of cases, argon is the shielding gas used. When TIG welding we usually have a pointed tungsten electrode but with aluminum, a slightly rounded tip works best. In the past, this had to be done manually, but when using a welder with an IGBT inverter there is no need. When welding aluminum on alternating current, the typical range is 25-35 A/C balance. At this level, the tungsten will naturally ball a little. This provides the best of both worlds: the tungsten is pointed enough for accuracy, while the slight balling makes for a stable arc cone.

The best way to learn how to weld aluminum is to practice – and use the right equipment. In addition to the right welding machine, the accessories you use will all depend on the type of aluminum alloy you’re welding. For example, the TIG filler rod should be matched to the grade of aluminum. Bear the thickness of the aluminum in mind too – use a thicker rod for thicker workpieces.

Which is the best process for welding aluminum?

Aluminum is usually TIG-welded, though MIG is another relatively common option. Aluminum is prone to warping and burn-through, so extra care must be taken to avoid damaging the metal.

How to seal aluminum joint welds

In this picture, the welder is seeing their welds getting progressively larger, and will eventually burn through. This is a result of the material getting hotter and the welder isn’t backing off the amps or moving their torch head away slightly.

In addition to properly preparing the metal with a good clean and degrease, a slow build-up to the heat via upslope time control can help lessen any damage to the metal as you practice.

The PowerWelds TIG 200P AC/DC welder is a great unit for welding aluminum. It includes features and technology to make welding aluminum – and other metals – easier. Let’s check it out:

PowerWelds 200Amp AC/DC TIG Aluminum Welder With Pulse

Best For TIG and Stick Welding—TIG-200 AC DC Tig/Stick Welder

The TIG200P AC/DC TIG welder provides 200 amps of alternating or direct current with TIG or MMA function. Designed with the modern welder in mind, this welder gives the user complete control with advanced features and technology, and durable design.

Includes MMA (stick) function
Upslope / downslope time controls
Amp control via foot pedal – remote control available
Real-time display
Multiple welding and torch control modes
Optional VRD for added safety when in idle mode
High-frequency start
IGBT inverter technology
AC Squarewave for accurate aluminum welding
Pulse current control

TIG welding is about accuracy. The TIG 200P AC/DC welder includes everything you need to weld a range of metals including aluminum, steel, nickel alloy, titanium, copper, etc.

Built for welding life

The TIG 200P AC/DC welder is built for heavy-duty. A smooth, shaped design gives the machine a less ‘bulky’ feel, while the exterior is built to withstand the knocks of everyday life. Sat in the shop or going out and about on the job, this hard-wearing TIG welding machine is built for reliability. Built-in safety measures automatically cut off the machine where abnormalities in current, heat, and voltage are detected, protecting the equipment. The unit is insensitive to temperature and humidity, guaranteeing consistency all year round.

Learn to Weld Professionally Fast - Even if you're A Complete Novice! TIG AC/DC aluminum welding results

powerwelds Welding Tips

7 May

Arc Welding: A Comprehensive Guide to the 5 Welding Processes

Arc welding is the welding process of melting two metals together. It uses electricity to create intense heat which melts the two metals together in a molten pool, effectively making them one material. This is called welding fusion and is the reason welded structures are so strong.

How does arc welding work?

Arc welding uses electricity to create a circuit between two metals: the base metal and the electrode, which is attached to the welding gun. When the circuit is broken by removing the electrode from the base metal, it creates an arc of electricity which is extremely hot – temperatures of 11,000 Fahrenheit can be achieved!

This molten pool of metal is what creates the weld – but it can be affected by gases and other contaminants in the air. A Welding Shield of inert gas is used to protect the weld while it’s in progress. Depending on the type of arc welding process you’re using, this gas will either be supplied externally (via the welding machine) or through an electrode (via a flux coating).

There are a few ways arc welding can be achieved, and the most common processes are:

Metal inert gas welding (MIG)
Tungsten inert gas welding (TIG)
Flux-cored arc welding (FCAW)
Welding Shield metal arc welding (SMAW)
Plasma arc welding

The Basics of Arc Welding

There are a few things in arc welding that don’t change, regardless of the process you’re using:

The materials being welded need to have a similar melting point, otherwise one will melt before the other, resulting in a failed weld.
Power can usually be supplied via alternating (AC) or direct (DC) currents. The type of power supply can affect the settings for the weld so always check before you start.
The more power, the higher the temperature of the arc. Manufacturers usually provide the standard settings for the equipment, but voltages should be changed to suit the job at hand.
The choice of electrode can massively affect the outcome of the weld.
Always clean the base metal with a metal brush or grinder before you start, even if you’re using a welding process that is compatible with contaminated base metals.
Safety is essential! You’re dealing with seriously powerful electricity and extremely high temperatures. Protect yourself. Wear safety gear and keep a suitable fire extinguisher nearby.

Below is a basic diagram of how arc welding works.

Arc Welding: A Comprehensive Guide to the 5 Welding Processes

Arc Welding Terminology

If you’re new to welding, there are a few technical terms you need to know.

Electrode – the material that transfers the arc to the base metal, and controls the weld

Arc – the arc of electricity between the base metal and electrode, which creates the heat required to weld

Gas shield – the shield of inert gas surrounding the weld, usually carbon dioxide, argon, helium or a combination of the three

Weld pool – the pool of molten metal that is formed from the base metal and electrode, and filler material if it is being used

Base metal – the metal that is being worked on

MIG welding

Highly versatile
Easy to learn
Semi-automatic process
Not suitable for outdoors
Can be used on metals of various thicknesses

MIG welding is arguably the most common type of welding, and the easiest type to learn. MIG stands for metal inert gas, though it is sometimes referred to as gas metal arc welding (GMAW). MIG welding is a semi-automatic process that is best suited to indoor applications where there is shelter from the wind.

The MIG welding process

A MIG welding gun uses a continuously fed solid wire electrode to create the arc of electricity to meld two metals together. An electric current is fed to the electrode which, in MIG welding, also acts as the filler material to improve the weld. The electrode controls the arc, which produces the heat to melt the electrode, filler and base metal. Shielding gas is supplied externally via the welding machine to protect the process.

MIG welding is suitable for a range of metals of varying thicknesses including steel, aluminium, nickel and various alloys. The shielding gas can also be changed, depending on the metals being used. Generally, MIG shielding gas is a concoction of CO2, oxygen and carbon. The voltage can also be preset via the MIG welding machine to suit the application.

What is MIG welding used for?

MIG welding is a highly versatile process that can be used for a variety of applications. It is most commonly used projects such as automotive repairs, structural steelwork and the manufacture of various objects such as furniture, computer components and machinery for agriculture or mining.

TIG welding

Uses a pointed electrode for precision
Produces high quality, attractive welds
Slow process
Minimal cleanup required
Filler material optional
Best performed indoors
More difficult to learn
Good for welding round things

TIG welding, also known as tungsten gas arc welding (GTAW). It uses a non-consumable, pointed tungsten electrode, which allows for superior precision. TIG welding produces high-quality welds when it’s done properly – but it is quite difficult to master the skill. TIG welding isn’t the easiest to learn but the results are worth it!

The TIG welding process

A TIG welding gun features a pointed tungsten electrode, a connector and a shielding gas. An arc is created when the electrode is applied to the base metal and then removed. It is a small, intense arc, which makes it ideal for high quality, precision welding.

TIG welding is one of the few processes that does not require a filler metal, but you can use one if needed. The absence of filler makes TIG welding clean, with little to no cleanup required upon completion of the weld. If you do use a filler, you’ll need to feed it manually by hand.

Various tungsten electrodes are available to suit different types of welds. Pure tungsten electrodes are the most common and are applicable for metals such as aluminium. The shielding gas should also be changed depending on the metals being used – argon is the most common. As with MIG welding, the external gas supply of TIG welding means it’s best performed indoors away from wind and draughts.

Where is TIG welding used?

With high precision and minimal mess, TIG welding is ideal for thin sheet metals and projects that will be on show. It is commonly used in metal art sculptures.

Stick welding

Fixed length electrode
Can be used on dirty, painted and rusty surfaces
Difficult to master
Some cleanup required

Stick welding is the most widely used form of arc welding. It is also known as shield metal arc welding (SMAW) and is suitable for both indoor and outdoor environments. Stick welding can be used on most common metals and alloys including steel, aluminium and iron. It can also be used on dirty and rusted surfaces, which makes it incredibly popular in the repair and maintenance industries.

Stick welding isn’t easy to learn though. It’s a highly skilled process – the ability to strike an arc can be difficult and the learning process is usually long, but well worth it!

The stick welding process

The ‘stick’ of stick welding is a fixed-length electrode, which is coated in a flux of powdered metals. When heated with electricity, the flux creates the shielding gas, while the melting electrode produces the filler material to create the weld with the base metal. As such, there’s no need for an external gas supply, which is why stick welding is usually the process of choice for remote and difficult environments.

Stick welding can be a bit messy and produce spatter, so there’s usually some cleaning up to do afterwards. The end result varies on the skill of the welder, but it must be said that stick welding doesn’t usually produce the most attractive of welds.

The characteristics of the weld can be changed by choosing a different flux coating and altering the angle of the weld.

Where is stick welding used?

Stick welding equipment is easily transportable, so it can be carried out almost anywhere. As there is no need for an external gas supply, stick welding is ideally suited to outdoor and hard to reach places. You can even stick weld in the wind and rain.

Flux Cored Arc Welding (FCAW)

High productivity
No external gas supply required
Easy to transport
Not recommended for thin metals
Can be used on dirty base metals
Some cleanup required

The flux-cored welding process is like a combination of MIG and stick welding. It’s fast like MIG and does not require a shielding gas, like stick welding.

The flux-cored arc welding process

As the name says, with FCAW the electrode has a flux core consisting of various compounds and powdered metals. The electricity is transferred through the electrode to the base metal, forming the arc. When heated with the arc, the flux produces the gas shield around the molten electrode, filler metal and base metal in the weld pool. The weld will be covered with residual slag which also provides protection, and it can be easily removed when needed.

Flux-cored welding is usually performed with a drag technique, where the weld gun is pointing back into the weld pool and being pulled away from the completed weld.

Where is flux-cored welding used?

Flux core arc welding is commonly used for heavy-duty industrial fabrication and manufacturing processes. It’s generally not recommended for beginners and those with little experience as the technique can be difficult to master.

As there’s no need for a shield gas, flux-cored arc welding can be used outdoors.

Plasma arc welding

Can be used on incredibly thin and thick base metals
Uses a non-consumable pointed tungsten electrode
High productivity
Precise and accurate
Produces high quality, attractive welds
Difficult to master

Plasma arc welding (PAW) is similar to TIG welding in that it uses a pointed tungsten electrode, and requires no filler material. Unlike with TIG welding, the electrode is positioned inside the torch. This allows the plasma to be kept separate from the shield gas, which envelops the arc and weld.

A plasma arc is incredibly powerful, bursting from the electrode at almost the speed of sound! Plasma welding arcs can reach temperatures over 55,000 Fahrenheit – over 5 times the heat of a typical welding arc!

A PAW welding torch uses pressurised gas to create plasma, which creates incredibly precise and strong welds that look great too. Plasma arc welding also offers a high productivity rate.

The Plasma arc welding process

Inside a PAW nozzle, gas is pressurized to create plasma. This plasma is then ionized so it can then conduct electricity, which produces the arc from the non-consumable tungsten electrode, which is pointed to increase precision. The arc that is produced is small and incredibly powerful. The power of the arc can be adjusted by changing the voltage on the machine. The shielding gas – usually argon or hydrogen – surrounds the weld.

Where is Plasma arc welding used?

Plasma arc welding can be used in a range of applications, though it is most commonly used for electronic applications. The aerospace, marine and healthcare industries also use PAW for its high precision.

Getting Started Welding

Just getting started with welding? PowerWelds has you covered. Check out our guide to getting started with welding, which covers the welding process in more detail and the equipment you’ll need for a successful and safe weld. You can also learn more about the career opportunities that welding offers – you can work anywhere from under the sea to the International Space Station.

If it’s the equipment you’re after, we offer a fantastic range of welding machines at entry-level prices, so if you fancy trying your hand at welding it won’t cost you a fortune. You can also stock up on welding equipment like guns, torches, helmets and accessories.

At PowerWelds, we build our equipment based on our customers’ feedback. And if you want to stand out, check out our awesome range of eye-catching welding helmets.

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6 May

10 Things You Should Know Before Starting a Welding Business

If you’re interested in starting your own welding business or are a beginner in the field, you should definitely check out our articles. The article discusses 10 things we wish you knew before starting your own welding business.

Here are the 10 key things you should know before starting a welding business:

Prioritize: Decide what activities are most important each day, such as getting work, preparing for jobs, managing your calendar, and following up with customers. Focus on gaining experience and earning respect rather than just profit in the beginning.
Manage Cash Flow: Avoid taking on too much debt by investing in used equipment as you need it. Don’t stress yourself out by overspending on unnecessary expenses like a new truck or top-of-the-line equipment.
Embrace Hard Work: Starting a welding business requires hard work and dedication. Don’t expect jobs to fall into your lap just because you have welding certifications. Put in the hours and effort needed to get your business moving forward.
Prioritize Important Tasks: Try to do your most important tasks first thing in the morning before getting bogged down with other responsibilities.
Grow Your Business Strategically: Don’t just take the same jobs at the same prices day in and day out. Learn to realize your worth and grow your business by hiring additional help or expanding your team.
Focus on What You Enjoy: Pay attention to the welding work that makes you happy and focus on doing more of it. It’s okay to pass on jobs that you don’t enjoy or are too advanced for your current skill level.
Optimize, Outsource, and Automate: Consider hiring someone to help with tasks like bookkeeping or quote preparation. Use auto-replies on social media to streamline communication with customers.
Engage with Your Social Media Audience: Take advantage of social media platforms to showcase your welding work and interact with potential customers. Having a business page and an Instagram account is essential.
Have Fun: Don’t forget to enjoy yourself! Starting a welding business is hard work, but it should also be rewarding and fulfilling. Take pride in your work and enjoy positive moments with your employees and customers.
Take Risks and Grow: Don’t be afraid to take risks and grow your business. Keep learning and expanding your skill set to stay ahead of the competition

As a welding community, we can all agree on one thing – there is a shortage of welders. It’s a topic that we see in articles almost daily.

We’re here to encourage those who are considering entering the trade, to assist those who are in school and may need help passing their certification tests, and to support those who are looking to broaden their skillset and learn about new processes and industry segments. We even welcome those who have the highest level of expertise to engage with us.

By coming together as a community, we can help make the welding industry a place that the younger generation and those looking to make career changes want to join. Let’s work together and help each other out!

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6 May

The Importance of Having a Built-In Air Compressor for Plasma Cutting Machines

Plasma cutting relies on ionized gas, or plasma, to cut through metal. To create this plasma, a high-pressure air or gas source is necessary. Traditionally, plasma cutters have relied on external air compressors to provide this gas source. However, modern plasma cutters like the 40A Plasma Cutter have a built-in air compressor that provides a reliable and efficient air source for plasma cutting.

So why is a built-in air compressor essential for plasma cutting? Here are a few reasons:

Convenience and Mobility

A built-in air compressor eliminates the need for an external compressor, which means you don’t have to worry about transporting and setting up two separate pieces of equipment. This can be especially convenient if you need to move your plasma cutter from the job site to the job site.

Stable Gas Output

The Plasma Cutter’s built-in air compressor provides a stable gas output, even after long-term use. This is because the compressor is designed specifically for plasma cutting, and can maintain a consistent pressure and flow rate.

Faster Cutting Speeds

Plasma cutting is already faster than traditional cutting methods like Oxyacetylene cutting. However, with a built-in air compressor, the cutting speed can be even faster – up to 2-3 times faster, in fact. This is due to the compressor’s consistent and efficient gas flow.

Less Deformation and Lower Costs

With a stable and consistent gas flow, plasma cutting with a built-in air compressor can result in less deformation of the metal being cut. Additionally, since the compressor is built-in, there are no additional costs associated with purchasing or maintaining an external compressor.

Precise Cutting

Finally, the Plasma Cutter‘s built-in air compressor allows for precise cutting, thanks to its pilot arc starting feature. This feature allows the cutter to start with a small electrical arc, which ionizes the gas and creates the plasma. This precise starting point results in a cleaner and more accurate cut.

Overall, a built-in air compressor is essential for achieving the best results with plasma cutting. With the 40A Plasma Cutter’s built-in reliable high-power air compressor, you can enjoy the benefits of efficient, precise, and cost-effective plasma cutting.

Are you looking for a reliable and efficient plasma cutter that can handle all your cutting needs? Look no further than our highly recommended 40A Plasma Cutter!

The Importance of Having a Built-In Air Compressor for Plasma Cutting Machine — 40A Plasma Cutter – Excellent Cutting Power Thickness16MM

With its built-in reliable high-power air compressor, this machine doesn’t require any additional gas source and provides stable gas output after long-term use. It can cut up to 16mm thickness of stainless steel with ease, and it’s 2-3 times faster than the Oxyacetylene cutting speed, saving you time and money.

The quick switch between the built-in and external air pump and the pilot arc starting function increases cutting capability and speed, while the overheat, overcurrent, and overvoltage protection ensure safe and secure operation. The simple operation and smooth precise cutting make it an ideal choice for both professional and DIY users.

So if you want a plasma cutter that can handle all your cutting needs, go for our highly recommended 40A Plasma Cutter. Trust us, you won’t be disappointed!”

powerwelds Welding Tips

30 April

Understanding the Components of MIG Welder Parts Diagram

Knowing your MIG welder’s parts is key for safety and better welding. A MIG welder parts diagram shows each component and its role, helping you fix issues or upgrade your welder.

It includes the power source, wire feeder, welding gun, shielding gas, and grounding cable. The power source activates welding, the wire feeder moves the welding wire to the gun, and the gun melts the wire to join metals. Shielding gas protects the weld, and the grounding cable completes the circuit.

Understanding these parts through the diagram enables you to manage your welder effectively, quickly solve problems, and improve your work.

Keep reading and check out the MIG welder parts diagram to enhance your welding skills.

Overview of a MIG Welder

A MIG welder, also known as a Metal Inert Gas welder, is a type of welding machine that uses a spool of wire to create an electrical arc that melts and joins two pieces of metal together. MIG welding is a popular welding technique used in various industries, including automotive, construction, and manufacturing.

MIG Welding Advantages

MIG welding has several advantages over other types of welding. It is a fast and efficient welding technique that can be used on a variety of metals, including aluminum, steel, and stainless steel. MIG welding produces a clean and precise weld, making it ideal for welding thin materials.

MIG welding is a versatile welding technique that can be used for a variety of applications, including welding automotive parts, repairing machinery, and fabricating metal structures. With the right equipment and training, you can become proficient in MIG welding and produce high-quality welds on a variety of metals.

Key Components of a MIG Welder: An Illustrated Diagram

MIG welding is a popular welding process that is used to join metals together. The basic components of a MIG welder include a power source, a wire feeder, a welding gun, and a ground clamp. The power source provides the electrical current needed to create the arc, while the wire feeder feeds the wire through the welding gun. The welding gun is used to direct the wire and create the arc, while the ground clamp is used to complete the electrical circuit.

1. Power Source

The power source is the heart of the MIG welder. It is responsible for generating the electrical current that is used to create the arc between the welding wire and the workpiece. The power source can be either a transformer or an inverter, and it is typically rated in amps.

2. Wire Feeder

The wire feeder is responsible for feeding the welding wire through the welding gun and into the weld pool. It consists of a motor, a drive roller, and a wire spool. The wire feeder is controlled by the welding machine and can be adjusted to control the speed and amount of wire that is fed into the weld pool.

3. MIG Welding Gun

The welding gun is the part of the MIG welder that the welder holds and uses to create the arc between the welding wire and the workpiece. It consists of a trigger, a nozzle, and a contact tip. The trigger controls the flow of electricity to the welding wire, while the nozzle and contact tip control the flow of shielding gas.

4. Gas Regulator

The gas regulator is responsible for regulating the flow of shielding gas that is used to protect the weld pool from contamination. It consists of a pressure gauge, a regulator, and a flowmeter. The pressure gauge measures the pressure of the gas in the cylinder, while the regulator and flowmeter control the flow of gas to the welding gun.

5. Ground Clamp

The ground clamp is responsible for connecting the workpiece to the welding machine. It consists of a clamp that is attached to the workpiece and a cable that is connected to the welding machine. The ground clamp ensures that the electrical current flows through the workpiece and completes the welding circuit.

Common Accessories and Attachments for MIG Welders

When it comes to MIG welding, some various accessories and attachments can enhance the functionality of your MIG welder. These accessories can help make your welding process easier, more efficient, and more precise. In this section, we will discuss some of the most common accessories and attachments for MIG welders.

Welding Wire: Most Essential Accessories for Mig Welding

One of the most essential accessories for MIG welding is the welding wire. Welding wire is the material that is used to create the weld. It is fed through the MIG gun and melted to form the weld. The welding wire comes in different sizes and materials, depending on the type of metal you are welding.

Another important accessory for MIG welding is the contact tip. The contact tip is the part of the MIG gun that comes into contact with the welding wire. It is responsible for carrying the welding current to the wire and guiding it to the weld. The contact tip needs to be replaced periodically to ensure a smooth and consistent weld.

A wire feeder is another accessory that can be used to enhance the functionality of your MIG welder. The wire feeder is responsible for feeding the welding wire through the MIG gun. It can be attached to the MIG welder or used as a separate unit. A wire feeder can help make the welding process more efficient and precise.

A shielding gas is another accessory that is commonly used in MIG welding. The shielding gas is used to protect the weld from contamination and oxidation. It is typically a mixture of argon and carbon dioxide. The shielding gas is fed through the MIG gun along with the welding wire.

Finally, a nozzle is an accessory that can be used to improve the quality of your weld. The nozzle is the part of the MIG gun that directs the shielding gas onto the weld. It can be made of different materials, such as copper or brass, and comes in different sizes and shapes. The nozzle needs to be cleaned and replaced periodically to ensure a clean and consistent weld.

Maintenance and Troubleshooting for MIG Welder Parts

Regular maintenance is vital to keep your MIG welder in optimal condition. Here are some maintenance tips to follow:

Keep the welder clean: Dust and debris can accumulate on the welder’s surface, causing damage to internal parts. Use a soft cloth to clean the surface of the welder regularly.
Inspect the wire feed system: The wire feed system is one of the most critical components of a MIG welder. Check the wire feed rollers, guide tubes, and liner for any damage or wear and tear. Replace any damaged parts immediately.
Check the gas flow: The gas flow is essential for a quality weld. Make sure the gas cylinder is full and the regulator is set to the correct pressure. Check for any leaks or damage to the gas hose.
Inspect the gun liner: The gun liner is responsible for feeding the welding wire from the spool to the gun. Check the liner for any kinks or damage and replace it if necessary.
Replace the contact tip: The contact tip is responsible for transferring the welding current to the wire. Check the tip for any damage or wear and tear and replace it if necessary.

If you experience any issues with your MIG welder, refer to the parts diagram to identify the specific component causing the problem.

Here are some troubleshooting tips for common issues:

Poor weld quality: Check the wire feed system, gas flow, and contact tip. Make sure the wire is feeding correctly and the gas flow is set to the correct pressure. Replace the contact tip if necessary.
Burnback: Burnback occurs when the welding wire fuses to the contact tip. Check the wire feed system and make sure the wire is feeding correctly. Replace the contact tip if necessary.
Wire feed issues: Check the wire feed system for any kinks or damage. Make sure the wire is feeding correctly and the rollers are set to the correct tension.

How Do You Use a MIG Welder Step by Step?

If you are new to MIG welding, using a MIG welder for the first time may seem daunting. However, with proper guidance, you can learn how to use a MIG welder step by step. Here’s a breakdown of the steps involved:

Prepare the Workpiece: Before you begin welding, ensure that the workpiece is clean and free of any rust, paint, or debris. This will help ensure a strong weld.
Set Up the Welder: Set up the MIG welder according to the manufacturer’s instructions. This typically involves setting the wire feed speed and voltage to the appropriate levels for your workpiece.
Prepare the Wire: Thread the welding wire through the machine and into the welding gun. Ensure that the wire is properly seated in the rollers and the gun.
Put on Safety Gear: Put on your safety gear, including a welding helmet, gloves, and protective clothing.
Position the Gun: Position the welding gun at a 90-degree angle to the workpiece. Hold the gun with both hands and brace your arms against your body for stability.
Start Welding: Pull the trigger on the gun to start the flow of gas and wire. Move the gun slowly along the joint, maintaining a consistent distance from the workpiece. Continue welding until you have completed the joint.
Finish the Weld: Once you have completed the joint, release the trigger and wait for the wire to stop feeding. Allow the weld to cool before removing any clamps or fixtures.

What Are the Three Advantages of MIG Welding?

MIG welding, also known as Gas Metal Arc Welding (GMAW), is a welding process that offers several advantages over other welding techniques. Here are three main benefits of MIG welding:

High welding speed: MIG welding allows for fast and efficient welding, making it suitable for high-volume production. The process is automated, which means that the welder can focus on other tasks while the machine does the welding. This makes MIG welding a popular choice for industries that require high-speed production.
Versatility: MIG welding is one of the most versatile welding methods, as it can be done semi-automatically or fully automatically and on a variety of materials such as steel, stainless steel, cast iron, magnesium, and aluminum. This makes it a popular choice for industries that require welding on different materials.
High-quality welds: MIG welding produces high-quality welds with faster speed. During welding, the welder uses a welding torch to continuously feed a consumable heated wire electrode and shielding gas. The shielding gas protects the weld from atmospheric contamination, which results in clean, strong, and durable welds. This makes MIG welding a popular choice for industries that require high-quality welds.

Conclusion

In conclusion, understanding the MIG welder parts diagram is essential for effective operation and maintenance of your welding machine. The diagram provides an accurate visual representation of the various components and their arrangement in a MIG welder. By understanding the different parts of a MIG welder and their functions, you can troubleshoot and repair any issues that may arise during welding.

The wire feeder is one of the most critical components of a MIG welder, responsible for delivering the welding wire to the welding torch. A motor-driven feeder mechanism precisely feeds the wire at a controlled speed, ensuring smooth and continuous wire feed, reducing the chances of wire jams or inconsistencies in the weld bead.

The contact tip of the welding gun is another vital part of the MIG welder, which supplies the electrical arc energy to the electrode. Typically, this contact tip is attached to the positive pole of the energy source, and the workpiece is attached to the negative pole. Striking the arc will complete the circuit, and the welding current passes through the contact tip of the welding gun to the electrode.

The MIG welder parts diagram also includes other essential components such as the gas nozzle, the gas diffuser, the torch head, and the power source. Each of these parts plays a critical role in the welding process and must be correctly maintained for optimal performance.

Frequently Asked Questions

What Are the Parts of MIG Welding?

MIG welding uses a welding gun that feeds a wire electrode into the welding pool. The wire electrode serves as a filler material that melts and fuses with the base metal. The welding gun also emits a shielding gas that protects the weld from atmospheric contamination. A MIG welder typically consists of a power source, a wire feeder, a welding gun, and a gas cylinder.

What is Inside a MIG Welder?

Inside a MIG welder, you will find a transformer or an inverter that converts the input power to the appropriate welding voltage and current. The wire feeder is responsible for feeding the wire electrode from the spool to the welding gun. The welding gun contains the contact tip, the nozzle, and the diffuser that control the wire electrode and the shielding gas. The gas cylinder contains the shielding gas that protects the weld from atmospheric contamination.

What Does a MIG Welder Need?

To operate a MIG welder, you will need a power source, a wire feeder, a welding gun, a gas cylinder, and a wire electrode. You will also need the appropriate safety gear, including a welding helmet, welding gloves, and protective clothing.

What Kind of Gas Do You Use With a Mig Welder?

MIG welding typically uses a mixture of argon and carbon dioxide or pure argon as the shielding gas. The choice of shielding gas depends on the type of metal being welded and the welding conditions.

How Do You Reset a MIG Welder?

To reset a MIG welder, you need to turn off the power source, unplug the machine, and wait for a few minutes. This will allow the capacitors to discharge and reset the machine. You should also check the wire feed system, the gas flow, and the grounding connection to ensure that they are functioning properly.

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