Welding

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2015L Welding Welder.png
QR code for General safety, found on both MIG and TIG welders.





General Safety Tips for Welding

Image of Welding Area with Ventilation Hood

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 for your use. 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.
Any Questions





MIG Welding (Metal Inert Gas)

https://www.youtube.com/watch?v=xeZstnEPVjU Mig Welding Tutorial (Only watch if you have never welded before)

Image of MIG QR Code, (Found on the MIG data poster in the welding shop)

For Safety refer to General Safety Tips for Welding

Setting up MIG Welder

MIG Welding Set up:
Settings Description
MIG Dial Controls (Wire Feed and Temperature)
Settings
  • 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
settings that are found under welder hood
This Diagram tells you what to set the welder to by thickness of metal

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

MIG Welding Techniques:
Image of Technique Description
Angle of Weld
Welder should be as close to perpendicular to the surface, and angled 20-30 degrees in the direction of travel shown
Shows Push and Pull
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

Stitch Welding
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.
Full Length Welding
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.
Fast and Slow Welding
Results of Fast and Slow Welds

Shutting down Welder and Clean up of Area

MIG Welding Techniques:
Cleaning the TIP General shutting down and cleaning
Cleaning Advice for MIG Welder
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)

https://www.youtube.com/watch?v=MKpsXXmBN10 Tig Welding Demonstration

Image of TIG QR Code, (Found on the TIG data poster in the welding shop)

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.
  • Use TIG for thin Sections and metals that can not be easily welded with other types of welding

Getting Started with TIG

  • Prep surface by removing any corrosion or oil with a wire brush (for Aluminum metal use Stainless Steel 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

TIG Setup for Steel:
Steel Metal Description
Dial to show settings for Steel
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 to a conical point
TIG tip Red for Steel
The RED tip is used for steel
TIG Steel tip
Make sure tip is free from build up and ground to a fine point
Creating Tip
Use machine sharpening grinder to grind to a point
TIG Setup for Aluminum:
Aluminum Metal Description
Dial to show settings for Aluminum
Use AC Current and an electrode with a Green tip end (100% Tungsten) Ensure that the tip is rounded properly
TIPS Green is used for Aluminum
Color Coded tips Green is used for Aluminum
Creating tip for Aluminum
Aluminum tip should like this before welding
Tungsten Grinding
Preparing Aluminum Electrode
  • 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
Aluminum Specifications
Choose correct electrode and filler rod based on the type of material and thickness of weld
  • Other Material-

Consult welding reference or experienced welder.

  • Amperage varies depending on the material thickness and type of weld

Adjusting the Torch

TIG Torch Adjustment:
Any Metal Description
Image of Welder on the upper Right
*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

Welding Technique

  • When Welding thinner materials a heat sink, consisting of a metal block (In the Shop the metal table will work), can be used to dissipate excess heat. Place this heat sink underneath the material when welding
Welding Technique:
Any Metal Description
Side View of proper Technique
Hold torch approximately 75-80 degrees from horizontal and the filler rod 15-20 degrees from horizontal
Don't touch the tip!
Tips for Welding
  • Never touch the tips
  • 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 weld material.
Diagram of correct Technique
After puddle is created use a circular motion or repeated crescent motion to move puddle while adding filler rod.