Welding

Apparel
All skin should be covered by non-synthetic fabric-polyester and the like; they will melt to the skin.A lab coat is available. Exposed skin will get sunburned from the electrical arc flash. Leather cloves shall also be worn to protect hands. "Caution- do not handle hot metal with gloves use the pliers".

Helmet
MIG Welding needs to have a Number 10 Lens; TIG welders can uses a Number 9 or 10 lens; "Higher the number the darker the lens"

DON'T WELD
Do not weld any metal with plating such as: Galvanized Metal, Chrome, Cad-plated, etc. Do not weld any metals that hold or have been in contact with Flammable liquids:   Gas Tanks, oil pans, etc.

Setting up MIG Welder
Choose the Correct wire gauge based on the type of material and thickness of weld. Set wire speed and thickness dials to appropriate settings (Proper settings to the thickness of metal to be welded are located under the hood of the welder) Ground welder to table or work to be welded Turn on CO2 tanks for the inert gas shield Turn on the MIG Welder Turn on the ventilation hood using the switch on the wall

Setting up Material to be Welded
Prep Surface to ensure a clean strong weld by wire brushing or grinding Put on all safety gear If the wire is protruding 1 cm past the nozzle, break it off on the table. DO NOT leave it stuck to the table Ensure others around know that you are welding by saying "COVER"

Welding Techniques
Welder should be as close to perpendicular to the surface, and angled 20-30 degrees in the direction of travel shown This is welder travel direction. Push is stronger, with more penetration in thick metals. Pull is weaker and with less penetration; good for thin metals Technique used to create strong welds with less distortion than a full length weld. Welder is placed in position, trigger pulled, and welder is moved back and forth motion for approximately an inch; an inch is skipped then process repeats. Highest strength weld, but most heat distortion and residual stresses. Welder is placed in position, trigger pulled, and moved in either a crescent moon path, or back and forth. See Image
 * Angle of Welder:
 * Push vs Pull welding:
 * Stitch Welding:
 * Full Length Weld
 * Results of Fast and Slow Welds

Shutting down Welder and Clean up of Area
Turn off the MIG welder Close the valve on CO2 tank Wrap ground cable around welder Wrap welder torch around the welder Unplug welder from the outlet and wrap cord around the welder Turn off the ventilation fan with the switch on the wall Put away Helmet, gloves, and shop coat Refer to Picture of Cleaning for the Machine

TIG Welding (Tungsten Inert Gas)
For Safety refer to General Safety Tips for Welding

TIG Uses
TIG welding can be used to weld Magnesium, Aluminum, Steel, Stainless Steel, Brass Alloys, Silver, Cast Iron, and Copper. Thin Sections and metals that can not be easily welded with other types of welding

Getting Started with TIG
Choose correct electrode and filler rod based on the type of material and thickness of weld (Review the Aluminum TIG Specs)

Prep surface by removing any corrosion or oil with a wire brush to ensure a clean strong weld Ensure others around you know you are welding and there is no potential flammable materials

Setting up the Machine for different Metals
Use DC straight polarity and an electrode with a Red tip end(2% Thoriated). When welding steel with DC straight polarity make sure the tip is ground toa conical point (see Preparing Steel Electrode) Us AC Current and an electrode with Green tip end (100% Tungsten) Ensure that the tip is round properly (see preparing Aluminum Electrode) Consult welding reference or experienced welder.
 * Steel
 * Aluminum
 * Other Material
 * Amperage varies depending on the material thickness and type of weld

Adjusting the Torch

 * Insert electrode by unscrewing the end of the torch and then sliding electrode into the collet.
 * For general use the electrode should extend 1/8 to 3/16 of an inch beyond the cup to ensure the shielding gas shields the weld

Preparing Steel Electrode

 * Make sure tip is free from build up and ground to a fine point
 * Use machine sharpening grinder to grind to a point

Preparing Aluminum Electrode

 * Aluminum tip created using a piece of copper to generate arc
 * Set amperage to max setting
 * Hold Electrode 1/8 inch from copper and press pedal
 * Heat generated causes tip to melt in to smooth ball

Welding Technique

 * Hold torch approximately 75-80 degrees from horizontal and the filler rod 15-20 degrees from horizontal
 * Hold the tip of the electrode about 1/8 inch away from piece and press the pedal down until an arc is created between the electrode and work piece. Keep the pedal depressed until puddle is created.
 * Ensure the tip of the electrode does not touch the molten weld puddle. This causes electrodes to become contaminated with the weld material
 * After Puddle is created use a circular motion to move puddle while adding filler rod
 * When Welding thinner materials a heat sink, consisting of a metal block, can be used to dissipate excess heat. Place this heat sink underneath the material when welding