The world of welding is as fascinating as it is important to major industries worldwide. Welding, in particular, is a captivating practice that can be accomplished within the confines of your garage, provided you have the safety equipment and knowledge necessary to employ the craft. Today, we will be taking a superficial look at welding while also highlighting a few tips and tricks that you can try in the comfort of your workshop. Let’s dive into our discussion so that you can get started.
Welding Tips & Tricks
TIG is an acronym that stands for inert tungsten gas, and that is the fuel source that powers your welding. Your TIG welding device is equipped with a non-consumable tungsten electrode. This electrode works to supply the welding arc you use in the welding process. What sets TIG welding apart from other types of welding is that you can ‘soft start’ or ‘soft stop’ your heat which allows you more control over the entire process. Armed with that knowledge, let’s shift our discussion toward a few key tips that you can employ on your next project.
Keep Your Surface Clean
We want to emphasise the importance of cleaning your surface materials before getting to work. TIG welding relies on a clean surface to get a healthy arc and a clean weld. So make sure to scrub down the surface you are working with before firing up your welding device.
Pay Attention To The Tip
Most new TIG welders will find this concept the hardest to wrap their minds around. First, it would be best if you kept the tip of your tungsten completely clean. If you accidentally touch it against the puddle, the tip is ruined, and you must regrind the tungsten yourself. A tell-tale sign that you’ve mucked with the tip of your tungsten is when your welding arc becomes wild and hard to control.
Grind Tungsten The Right Way
One of the biggest beginner mistakes has to do with grinding your tungsten. Grind your tungsten in an even fashion by pointing in the length-wise direction rather than the wide direction. You’ll need to follow this tip if you want to have an even arc that is easy to direct and work with. TIG welding can be fun and rewarding, but it still requires preparation. Use our tips and your resources to prepare yourself for your next welding project. For any of your welding needs, contact K&K Steel.
How To Fix 8 Common Welding Problems?
Over the years, these welding techniques have been simplified with superior welding equipment. Unfortunately, many operators can forget essential steps when performing the weld with such equipment. However, when these same operators run into trouble, they cannot diagnose and correct problems. Here are some common welding issues and how to correct them.
In gas metal arc welding (GMAW), a common unwanted side effect is creating what welders call a spatter. These are droplets of molten material that are produced near the welding arc. Spatter happens when welding currents are too high, incorrect polarity, or insufficient gas shielding. To avoid spatter, reducing the welding current and arc length is recommended. In addition, the welder can check to see if there is the correct usage of polarity for the consumable. Last, it is a good idea to check the shielding gas type and flow rate and clean the gas nozzle and increase the torch-to-plate angle.
Porosity is caused by the absorption of nitrogen, oxygen and hydrogen in the molten weld pool, which is then released on solidification to become trapped in the weld metal. Causes for porosity include the presence of moisture, rust, grease or paint on the plate edges, insufficient gas shielding, or when the welding is done onto small gaps that have air in between.
To avoid porosity in a weld, the welder should re-bake or use fresh welding consumables and check the welding torch for leaks. Having dry and clean plate edges helps too. It would also be a good idea to check the shielding gas type and flow rates, clean the welding device’s gas nozzle and make sure the torch to plate angle is not too large or small.
Undercuts occur when the arc voltage is too high or when the arc is too long. It can also happen if there is incorrect electrode usage or angle or if the electrode is too large for the thickness of the plate. In addition, undercuts tend to happen if the travel speed is too quick.
Besides watching the speed, it is important to check for proper manipulation of the electrode used:
- It is recommended that welders do not use a bigger than needed electrode because if the amount of molten metal becomes too big, there will be an undercut.
- It is essential to look after how much weave is used.
- When making a horizontal fillet weld, do not hold an electrode near the vertical plate.
Deformation happens during the contraction of welded metals when it is cooling and hardening. This occurs if the welding sequence is not suitable for the intended weld, there are too many thin beads, poor plate fit-ups (insufficient clamping) before welding. Some good solutions to avoid deformation are welding from both sides of the joint, welding from the centre out (in opposite directions), using a larger electrode, and firmly clamping. Changing the sequence of welds, or the location of the joint, or making fewer passes, can also help reduce
In any construction, every crack (regardless of size) is considered a defect. It can be dangerous because small cracks have the potential to become larger over time. In addition, it is not as simple as filling the gap with material because cracks need to be ground out, and then a new weld is performed to correct the error. Since this is tedious, prevention is preferable to the cure.
To avoid cracks, it is necessary to spend time grinding, cleaning, filing or deburring the edges of the plates, so they easily fit together. It would be good to reheat both sides of the joint since having the right temperature matters and clamp the plates together. And before going on to weld, check to see if you have the right amount of heat dialled up by testing your machine settings.
FAQs About Welding Tips And Tricks For Home Construction
There are four main types of welding. MIG – Gas Metal Arc Welding (GMAW), TIG – Gas Tungsten Arc Welding (GTAW), Stick – Shielded Metal Arc Welding (SMAW) and Flux-cored – Flux-cored Arc Welding (FCAW). We dive deeper into each type of welding here.
The skeleton of a welding symbol has an arrow, a leader line (attached to the arrow), a horizontal reference line, a tail, and a weld symbol (not to be confused with welding symbol, which refers to the whole thing. See symbol 1). Hold on, if you're already lost, don't panic. It'll all start making sense soon.
To ensure that the operator is safe while welding, it is essential to follow these tips. Below are some safety welding practices.
- Wear proper clothes
- Remember that any exposed skin is susceptible to the damaging effects of UV and infrared rays when welding. Furthermore, sparks can easily catch in open pockets, cuffed pants or shirts that are not completely buttoned. It is important to wear clothes that don’t expose the skin. Also, make sure not to keep any matches or butane lighters in your pockets.
- Wear the appropriate gear
- Before anything else, every welding personnel should be provided with proper welding personal protective equipment. This equipment includes welding gloves, helmets, leather jackets and boots. Apart from these gears, a respirator is highly required, especially when welding galvanised steel.
- For best foot protection, use high-top leather shoes or boots. Make sure that the pants should go over your shoes. Avoid using cloth shoes since they will smoulder easily.
- Make sure that there is enough clean breathing air.
- Smoke and fumes that are emitted during welding can create a health hazard. Toxic fumes accumulate easily, and shielding gasses may also replace breathable air. Thus, working in a well-ventilated area is crucial.
- If the welder is working in confined spaces, use an exhaust hood. This can remove fumes from the space and ensure enough clean air to breathe.
- Keep welders’ eyes protected
- A welder may experience arc flash with just a few seconds of exposure to welding arc’s rays when welding with unprotected eyes. It is a painful condition in the eyes that may last several hours after exposure.
Hence, always wear proper welding helmets with filter shade. This is to protect the welder’s eyes when welding. In addition, choose approved safety glasses with side shields and ear protection.
Incomplete Penetration And Fusion
Incomplete root fusion is when the weld fails to fuse on one side of the joint in the root. Incomplete root penetration occurs when both sides root region of the joint are unfused. These issues tend to happen more in consumable electrode processes (MIG, MAG, FCAW, MMA and SAW), where the weld metal is ‘automatically’ deposited as the arc consumes the electrode wire or rod. Solutions include using a wider root gap, electrodes whose diameter size is approximately the gap width of the root. In addition, when welding, it would be good to use a lower travel speed and weave between the plate edges.
Slag inclusion is the small particles of flux that become trapped in the weld metal, which prevent complete penetration of the weld. The way to prevent this is to have well maintained flux-coated consumables. In addition, having the correct current, voltage, and good arc characteristics would be necessary to ensure quality welds with complete fusions when running through.
Incorrect Wire Delivery
When welders start hearing a chattering sound within the gun cable, there could be an issue with the wire delivery system. In this instance, this is always to do with ensuring the correct set-up of the equipment and maintenance. Sometimes, welders make the mistake of using too large tips for the application that can lead to some of the other welding problems listed above.
Some tips include ensuring that the contact tip of the gun is properly functioning and double-checking the size of the wire that will be used. It is a good idea to check the tip of the wire to see if it is worn out and needs to be replaced. As for the drive rolls, it is worth checking them as they do wear out. Always make sure that the drive rolls and guide tube are within proximity.
Things To Know On Welding Galvanized Steel Safely
In the metal fabrication process, welding galvanised steel is an important and valuable technique. This method is especially used when making galvanised steel gratings or steel wire cloth.
Defining Galvanised Steel
Galvanised steel is regular steel sheets covered in zinc, making it rust-resistant. A regular steel sheet is usually made of iron. But this material is susceptible to rust when exposed to moisture.
Galvanised steel is one of the most common kinds of steel in the market today. One of the main reasons is its extended durability. It also has the same elasticity as steel. Aside from that, it has the corrosion-resistant features of the zinc-iron coating. Furthermore, galvanised steel is mostly used for modern steel frame buildings. Some industries that utilise galvanised steel include wind and solar, automotive, construction, and telecommunication industries.
Material issues when welding galvanised steel
There are certain issues that welders might encounter when welding galvanised steel. Here are some of them.
- Corrosion issues
- Corrosion resistance is a common problem when it comes to welding galvanised steel. The idea of galvanising is to prevent the steel from rusting. However, it would be best to get rid first of the galvanising zinc across the welding area, thus, uncovering the area for corrosion.
- The only way to work this out is to galvanise the steel again after completing the welding. Although it is time-consuming, it is a practical method to maintain the corrosion-resistant property of the material.
- Coating issues
- Apart from the health issues that welding galvanised steel can pose, there are other problems that you may encounter. One of the challenges of welding galvanised steel is the zinc coating found on galvanised steel. This material can compromise the weld. Since there is a coating, it makes the penetration more difficult. Moreover, it can cause a weld to have inclusions and porosity.
- To weld galvanised steel successfully, a skilled welder is required. Furthermore, to solve the coating issue, the zinc coating should be removed from the area where you are welding. The filler material can also be used on the zinc-coated portion of the welding area.
Proper Care And Maintenance To Protect Galvanised Steel
To avoid or minimise the issues when it comes to galvanising steel, it is crucial to have general care and maintenance of your products. Here are some important guidelines to do this.
- Galvanised steel products should not be exposed to pH levels between 6 and 12. This is because the galvanised coating can undergo greater corrosion than usual.
- There should be no direct contact of the galvanised steel products with dissimilar metals, including brass and copper, specifically in corrosive environments.
- Avoid cleaning or washing galvanised steel products abrasively. A thin barrier film of insoluble zinc corrosion material developed on the galvanised steel’s outer space. This is also known as a patina. This protects the galvanised steel from corrosion. Harsh cleaning will wash away this protective film. When this happens, more zinc will be consumed. This will eventually reduce the life of the galvanised steel product.
- For galvanised steel products located in highly corrosive areas such as coastal and heavy industrial places, make sure to rinse the product with potable water regularly. It also should not be exposed to rain and sun.
- Ensure not to store the galvanised products in damp and poorly ventilated areas for a very long time. The storage location should be dry and has good ventilation.
Health Issues Regarding Welding Galvanised Steel
Other than the material issues, there are also health risks that operators may encounter. To learn more about these hazards, read more below.
- Metal fume fever
- When welding galvanised steel, the zinc coating easily vaporises. This will form zinc oxide fumes that will mix with the air. This gas may have short-term effects on your health, also known as “metal fume fever”. Welders may experience flu-like symptoms once they inhale the fumes. These may include nausea, headaches, high fever, shivers and thirst. The symptoms will usually go away within 48 hours of exposure.
- Long term health concerns
- There is a small lead content on the galvanised coating. When welding, this lead will vaporise and form lead oxide fumes. These gases can cause long-term health problems such as lung and brain cancer and even complications in the nervous system. Thus, wearing the proper safety equipment is crucial to avoid these health problems.
- Safety gear and proper training
- The safety concerns mentioned above all boils down to the lack of welder safety training. The welder must be well-trained. They should keep the welding shield and welder’s face from the fumes. The welder should also be in a proper position to maximise the clean airflow. Apart from that, this will prevent the oxidised dust from gathering inside the welder’s shield.
For safety purposes, the welder should be provided with a high-quality mask. They should also be fully trained on the safety measures in welding.
Welding steel can be risky for people who have no prior knowledge of the metal fabrication process. It is also important to learn safety precautions when welding these materials. The right approach to welding steel is the best way to deal with certain issues. If you need help with your metal fabrication needs, do not hesitate to contact a skilled and experienced sheet metal fabricator in your local area.