PROTECTED ALL ROUND WITH THE RIGHT WELDING EQUIPMENT

Working on the welding machine all day is a huge burden. Due to the changing light conditions and the high UV radiation, the eyes quickly get tired. The welding smoke also helps that the concentration begins to suffer after four hours at the latest. There is also the risk of "flashing" through the arc - and not to forget the reddening of the skin and burns when welding aluminum if the neck seal of the welding jacket is not properly closed.

EYE PROTECTION - NO FLASHED EYES

HOW TO PROTECT YOUR EYES FROM THE ARC

A welder must constantly look into the arc to control the weld pool. The eyes are exposed to ultraviolet radiation, infrared radiation and visible light rays, which are harmful to health in high concentrations. Reliable eye protection is therefore particularly important - either with a hand shield or a fully automatic welding helmet from Helmet Adviser. The second variant is much more comfortable because the welder has both hands free.

EYES BLASHED WHEN WELDING

Everyone knows the uncomfortable feeling of looking directly into the sun. It is similar with the arc - however, the radiation is much stronger here. A short eye contact with the arc is usually not a problem: the eye is blinded but does not take any damage and recovers quickly. However, anyone who looks into the arc several times or for a longer period of time permanently damages his eyes - this is called "flashing". When this effect occurs and how long it takes for the eye to regenerate from it cannot be clearly stated. The complaints usually go away after 24 to 48 hours without long-term consequential damage.


Welders often describe the painful feeling of flashing like a "welder's eye": those affected are extremely sensitive to light and prefer to keep their eyes closed. An antibacterial ointment from the pharmacy usually helps very effectively to relieve the pain. Cold compresses are also recommended to cool the eye.

RESPIRATORY PROTECTION - PROTECTED FROM WELDING SMOKE

HEALTH RISK WELDING SMOKE

Welding smoke is a mixture of gases and small particles that are inhaled through the mouth and nose and can penetrate deep into the lungs. In total there are more than 40 different substances in the welding smoke. These come from the processed material itself, from the additives or from coatings such as paints and coatings. Among other things, they can lead to breathing difficulties or change the genome in such a way that diseases result from it.

How to protect yourself from welding smoke:

• STATIONARY

Stationary suction device at the work table.

• SUCTION

Mobile suction system in connection with suction device on the burner head.

• AIR FILTER

Fresh air supply and air filter system in the welding helmet.

What types of welding are there?

Welders are often referred to as different professional groups. But this is not correct, because it is primarily the welding processes that distinguish them from the others.

Fundamentally, there are a variety of different types, with four welding processes now being the most represented. We are talking about:

• Gas welding
• TIG welding (tungsten inert gas welding)
• Manual arc welding (E-welding)
• MAG welding (metal active gas welding)

These four types have now clearly stood out from the others and are the solutions of today. This blog post will deal with the different types of welding and their areas of application.

1. Gas welding

Gas welding is one of the older methods, but here and there it still has a reason to exist. This process is characterized in that the weld seam is heated and, as a result, is melted.

The oxyacetylene welding machine acts as a heat source and is jointly responsible for ensuring that the melt is protected against oxygen and oxidation. Gas welding is mainly represented in the trades. Gas welders are often used to supply gas and water pipes.

But that's not all, gas welding is still very popular in outdoor assembly or general pipeline construction.

2. TIG welding

Tungsten inert gas welding is an integral part of welding and is indispensable. The arc is essential in this welding process and the defining feature is that it is positioned between the workpiece and the so-called tungsten electrode.

The tungsten electrode has a high melting point and therefore does not melt during the process. This welding process uses an additional material that is held in the arc and melts together when the workpiece is welded.

Inert gases are mostly used, which avoids a chemical reaction with the air. Metal processing is one of the typical areas of application for TIG welding. But TIG welders are also always in demand in apparatus construction, tank construction or the general pipeline construction.

3. Manual arc welding

Arc welding also uses the arc that is used between the workpiece and the electrode. In contrast to TIG welding, the situation with this process is such that the electrode serves as a filler and consequently melts.

In addition, other electrodes are used - we are talking about stick electrodes. These have a casing and this in turn ensures that appropriate protective gases are released.

This protects the melt from a chemical reaction with the air. Compared to the other processes, the process, also known as electric welding, is one of the oldest in the industry. Typical areas of application are in overhead pipe construction, but also in manual steel or bridge construction, manual arc welding is often used.

4. MAG welding

MAG welding (metal active gas welding) uses a mixture of different active gases and is a process that is often used in metal construction.

The gases mentioned influence the quality of the weld seam and ensure that there is no chemical reaction. MAG welding is also used in vehicle and mechanical engineering far from metal construction.

All four types of welding are essential for the economy

Ultimately, it can be said that the four types presented in this article have long been an integral part. Even though industrial welding is outclassed by many, electrode manual welding is still considered indispensable.

Anyone who is faced with the selection of the right welding process should deal with the topic in peace. A premature decision can involve tailor-made changes for the welder himself. But that's not all, because companies must also think carefully about which process to use before implementing a project.

The selection of the welding process chosen for the respective project decides how successful the production will look - especially since there are also economic aspects and these must also be taken into account.

What is Mig Welding? Its Different Arc and Advantages & Disadvantages

MIG welding (metal welding with inert gases) is a so-called arc welding process.

The welding wire (2) is continuously and automatically unwound from a coil by means of a motor at a variably adjustable speed. The wire is led directly and directly to the welding point using the contact sleeve (1). The welding wire melts off immediately. During the MIG welding process, shielding gas (3) is fed through a nozzle. This prevents the penetration of oxygen into the weld pool (4) and thus protects against oxidation. This would weaken the weld seam and consequently lead to inferior quality. The finished weld seam is also called a weld bead (5).

While MIG welding works with active gases and steel is primarily connected, MIG welding uses non-ferrous metals to weld inert gases. Argon is used as the inert gas, in rare cases also helium (which is more expensive) or their mixtures. Since the gases used do not react with the base and filler materials, MIG welding is mainly used to connect copper, aluminum or aluminum alloys and other non-ferrous metals.

The inert gases allow welding at much higher temperatures. The possibility of oxidation of the weld seam occurring is thus excluded, which in turn has a very advantageous effect. Because of weather influences such as If the shielding gas is driven away, MIG welding can only take place in closed rooms. The welding process outdoors would therefore take place without the useful oxidation protection and thus a weld seam of inferior quality would result, which would be much more sensitive to rust and not as stable.

This type of welding is used to manufacture tanks and pipes, in mechanical engineering, in precision engineering or in nuclear technology.

Differentiation between different arcs in MIG welding

• Short arc welding

Root welds and welds in uncomfortable positions or constrained positions are carried out in low power ranges. Thin sheets are primarily connected. An almost smooth material transition is created because only a few spatter and fine drops occur during welding.

• Spray arc welding

Rather thicker sheets are connected here. The low-splash, fine-droplet and short-circuit-free material transfer results from the large melting and high speeds when welding with argon mixed gases.

• Pulse arc welding

This type of arc welding is used for all sheet thicknesses. It is welded with argon-rich mixed gases. This welding process is used in the medium performance range. Here, a pulse current is placed over the base current. It is possible to regulate the thickness of the droplets generated during welding as required. This results in a short-circuit-free, with minimal formation of splashes and even, fine-droplet transition of the materials.

Advantages of MIG welding:

No slag is produced in MIG welding. The shielding gas shields the weld seam from the influence of oxygen and therefore prevents the risk of oxidation. Due to the high pace of work, the materials to be welded have less heat. Only slight deformations are to be expected. This welding process is also the best method because of the possibility of welding in constrained positions. It became the most widely used welding process. The high strength of the weld seam reduces the intensity of the rework.

Disadvantages of this welding process:

If MIG welding were used outdoors, it would inevitably lead to the inert gases being blown away. Therefore, this gas metal arc welding can only be carried out in closed rooms. It is not easy to master and requires a lot of experience. Particular attention must be paid to thorough weld preparation.

What is Tig Welding? Its Advantages and Disadvantages

Tungsten inert gas welding (TIG welding) is a protective gas welding process and is one of the fusion welding processes. It is used wherever the highest quality and spatter-free weld seams are important. TIG welding is suitable for stainless steel, aluminum and nickel alloys as well as thin sheets of aluminum and stainless steel. Applications can be found in pipeline and tank construction, in portal construction or in the aerospace industry.

TIG WELDING: HOW IT WORKS

With TIG welding, the required current is supplied via a tungsten electrode that is temperature-resistant and does not melt. An arc arises from this electrode, which heats and liquefies the material. There is a protective gas nozzle around the electrode. This protects the heated material from chemical reactions with the ambient air. The noble gases argon, helium or mixtures thereof are used for this. The inert, i.e. non-reactive gases prevent chemical reactions with the molten pool and the heated material. This ensures high quality welds.


Because the tungsten electrode does not melt, the filler material is added manually or mechanically using an external wire feeder during TIG welding.

THE TUNGSTEN ELECTRODE

The tungsten electrode is the heart of TIG welding. At 3,380 degrees Celsius, tungsten has the highest melting point of all pure metals in the periodic table. As a result, the electrode does not melt while an arc is emanating from it, which heats and liquefies the material. The electrodes are manufactured using a sintering process. To improve their properties, they can be alloyed with oxidic additives. Depending on the alloy, the electrodes are marked in different colors:

• PURE TUNGSTEN (WP) (GREEN):

         / Smooth spherical electrode surface
         / Ignition problems with direct current
         / Low current carrying capacity

• RARE OXIDE (WS2) (TURQUOISE):

         / Suitable for all materials
         / Very good ignition properties
         / Longer service life than WT or WC electrodes

• CEROXIDE (WC 20) (GRAY):

         / Suitable for all materials
         / Very good ignition properties

• LANTHANOXIDE (WL 20) (BLUE):

         / Longer service life than tungsten thorium or tungsten cerium oxide electrodes
         / Poor ignition properties


ADVANTAGES OF TIG WELDING

• No formation of welding spatter
• Optically high quality welds
• All welding positions are possible
• Very high weld quality

DISADVANTAGES OF TIG WELDING

• Requires high skill
• Low welding speeds
• Rust must be removed when preparing the weld
• Not suitable for large workpiece thicknesses

These 7 tips make you a welding hero - Aluminum welding with Eric

The engine of your Simson or lawnmower has broken? You cannot buy the damaged part because it is no longer manufactured? Before you think desperately that that's it and the device can only be stamped in, here's the reassuring message: the whole thing can be repaired - and the magic word is "aluminum welding".

We have compiled Eric's most helpful tips and tricks for you: 

• Preparation is half the battle
• So you avoid that it burns
• Think good handling
• So you can weld quickly
• It depends on the nozzle size
• Choose the correct amperage
• Finally, the post-processing
• Addition: What equipment does Erik actually use?

1. Preparation is half the battle

So you shouldn't start welding right away, but first prepare yourself well. Prepare everything you will need and above all: First clean the part to be welded thoroughly.

You can heat the material with a hot air dryer, for example, to remove paint and dirt. You can use a stainless steel wire brush for cleaning.

For pre-cleaning, material can also be blasted with stainless steel balls so that the surface is nicely compacted. Erik follows this approach, for example, in the episode "Weld on the Simson motor housing".

In the last step, use acetone and clean the area to be welded again properly with a simple cloth.

Why acetone? You will find out in the next tip.

Thorough cleaning is part of good preparation

2. So you avoid that it burns

It could start burning when welding, but it shouldn't.

To avoid this, you should definitely use acetone when cleaning and not thinner. Acetone evaporates quickly, but a dilution could accumulate in small pores of the material. This can increase the risk of fire when welding. So take acetone and you're on the safe side.

For a good end result, you shouldn't ignore the dirt that can still come out of the material during welding.

So put a stainless steel brush close at hand, interrupt the welding process when you see dirt and remove it from the weld with the stainless steel wire brush.

Erik occasionally cleans the weld with the stainless steel wire brush

3. Think good handling

For welding itself, it is important to make handling as pleasant as possible and to be able to work quickly.

Therefore, lay the hose package of the welding torch on your lap for better handling. Especially when water cooling is included, the whole thing is a bit more difficult. So you don't have the weight of the hose on your wrist during welding and the torch is easier to use.

The right material thickness is also crucial for speedy work.

Especially with repair welding - as we see some in this season - a lot of material has to be applied during welding. We therefore recommend using a not too thin aluminum wire for stapling. Erik also prefers to use a slightly thicker wire (e.g. 3.2mm ALSI 5), as can be seen in the following "Simson engine cover repair weld". This makes welding faster and easier.

Work with the right filler metal

4. So you can weld quickly

Now you already know how to handle the hose package and the material thickness so that everything works well during welding. But of course you can keep more in mind to get to the desired result quickly.

For example, if something has broken off in the part to be repaired, work your way up from the lowest point. So you can build up the material nicely evenly.

And because "quick and even" is exactly what we want when welding, here's another tip: don't be too timid, but press the aluminum wire into the weld pool properly. You will see how good the welding work is then.

Also keep in mind that grinding is still required after welding. Therefore do not save on the material, but always weld a little more. So you have a good buffer later when grinding away and everything remains nice and stable.

Speaking of stability: If you also have the option of welding something from both the front and the back, then use this option. Erik points this out in the following "Repair welding on the lawn mower". He then welds the lid from both sides, which can make the whole thing 100% tight and stable again. So don't miss out on such an opportunity if you want to work cleanly.

Erik also welded the lid from the inside

5. It depends on the nozzle size

As Erik explains in the following "Welding on the fan wheel from the Simson blower motor", there are nozzles of different sizes for burners.

In this case, it is quite narrow between the blades of the fan wheel. In such cases, we recommend that you use a smaller nozzle so that you have better freedom of movement when welding. The right nozzle size will help you add the filler material well and see the weld pool. So you can build up the material even in narrow areas.

Don't forget to increase the amount of gas. This is because less gas flows through the smaller opening of the nozzle. For example, like Erik, you could increase it from 8 to 10 liters / minute.

So remember: Use a small nozzle to access tight welding work.

Use a smaller nozzle if you have less space

6. Choose the correct amperage

When welding, it is important to choose the right amperage. Depending on how thin or thick the part to be welded is, the amperage should also be higher or lower.

But it is also no problem to start with a certain number of amperes and then to regulate the strength during the welding process. For example, if you notice that the workpiece is getting too warm and the seam is starting to sink in, then adjust the current down by 20 to 30 amps before continuing to weld.

However, if you can determine from the start that the sheet thickness is very low, then set the starting current lower from the start.

Erik sets the welding machine to 160 amps, for example, in the "Welding the DKW gear cover" sequence. He also uses a suitable tungsten electrode for the TIG needle and works with a gas flow of 8 liters / minute.

Erik did not have to regulate the number of amps in our video and was able to maintain the set amps throughout the welding process.

"Choose the right amperage when welding"

7. Finally, the post-processing

The last and no less important step in welding is post-processing. It is important that you bring the necessary finishing touches to the material so that the repaired area again corresponds to the original look. The good thing about aluminum: It is relatively soft, which means that it can be quickly sanded away.

During the grinding process, make sure that all welding points are sanded down. However, since the weld seam creates the necessary hold when welding aluminum, it should not be completely sanded. In the episode "Repairing the Simson Engine Side Cover" you can see how Erik grinds the weld.

Be it a hand file, polishing disc, angle grinder, etc. - there are various options available for post-processing. Choose the variant that suits you best, so that you can best bring the repaired part back to its original shape when grinding.

Finally, you have the option of using a heat protection spray. Erik used this for the gear cover, for example.

Et voilà, it is no longer noticeable that something had to be repaired at all.

Post-processing is the last step

As you can see, thanks to the aluminum welding process, the new motto is: “Repair and don't throw away!”. We hope that the tips and tricks from Eric "Aluminum spoon" and we will help you with your own welding work with aluminum. For more information, drop by the current season of “All about weld” and feel free to leave us a comment there.

What is Welding? How does the arc occur?

Welding is the connection of workpieces using heat and / or compression, so that the workpieces form a unit. When welding, the heat source is an arc flame that is generated by the electricity of the welding power supply. Arc-based welding is referred to as arc welding.

The joining of the workpieces can only be based on the heat generated by the arc, so that the workpieces fuse together. This method can be used for example in TIG welding (tungsten inert gas welding).

Usually, however, the workpieces are welded to one another with the aid of an additional material via the weld seam or weld point. For this purpose, a wire feed device is used via a welding torch (MIG / MAG welding) or a welding electrode by means of a manual feed. In these processes, the filler metal must have approximately the same melting point as the material to be welded.

Before welding, the edges of the workpieces are put together so that they form a suitable weld joint, e.g. a V-joint. In the course of the welding process, the arc welds the joint edges to one another via the filler material, which creates a liquid weld pool.

In order to obtain a permanent weld connection, the weld pool must be protected against oxygen enrichment (oxygenation) and influences from the ambient air, e.g. with the help of protective gas or slag. The shielding gas is led to the liquid weld pool via the welding torch. The welding electrode can also be coated with a material that represents a kind of protective bell and serves to ensure that slag forms over the weld pool.

The best known welding materials are metals such as Aluminum, steel and stainless steel. Plastics can also be welded. In plastic welding, the heat source is hot air or an electrical resistance.

How does the arc occur?

The arc required for welding is an electrical discharge between the welding electrode and the workpiece. The arc is generated when a sufficiently large voltage pulse (trigger ignition) develops between the workpieces or the welding electrode is tapped on the material to be welded (contact ignition).

The arc is the basis of arc welding. It welds the starting material and the filler material, producing the weld seam.

Here, the voltage discharges like a lightning strike, allowing electricity to flow through an air gap, resulting in the generation of an arc that is several thousand degrees Celsius at a maximum of 10,000 degrees Celsius (18,000 degrees Fahrenheit). A continuous current to the workpiece is generated by the welding electrode via the welding current supply and for this reason, the workpiece must be earthed in the welding machine via an earth cable before the welding process is started.

In TIG welding, the welding electrode is an unusable tungsten electrode and the filler metal is fed manually to the welding point. In MIG / MAG welding, the electrode is a welding wire that is passed through the welding torch. The wire melts and becomes a filler in the workpiece.

In order to obtain a smooth and permanent weld, the welding arc should be stable. It is therefore important to use a welding voltage and to select a wire feed speed that is suitable for the material to be welded and its thickness.

In addition, the welding technique affects the fineness of the arc and consequently the quality of the weld. The distance from the welding electrode to the seam and uniform speed of movement of the welding torch are important factors for successful welding. Estimating the correct voltage and wire feed speed is an important part of the skills of the welder.

However, modern welding machines offer several options that make the welder's work easier, such as the storage of previously used welding settings or the use of preset synergy curves, which makes it easier to set the welding parameters for the task ahead.