Monday, September 26, 2011

ANCHOR BRAND 6010-1/8X5 MILD STEEL ELECTRODE - 5 LB

ANCHOR BRAND 6010-1/8X5 MILD STEEL ELECTRODE - 5 LB"ANCHOR BRAND" ELECTRODE

Dia.: 1/8 in
Tensile Strength: 76000 psi [Max]
Material: Mild Steel
Wt.: 5 lb
Packing Type: Package
Recommended for pipe, and noncritical small diameter piping.
Traditional DC+ choice for dirty, rusty or coated steel.

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1/16" Eazy Strike Rod-6013

1/16For 110 volt welding machines. With Easy Strike igniter tip to help eliminate problems a less experienced welder might encounter while starting the arc. Easy to use for homeowners, handymen, and hobbyists. Can be positioned flat, horizontal, vertical oroverhead. Coated with titania potassium for AC, DCEP or DCEN current. 60 tensile strength.

Welding Electrodes Price: $8.99


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10 TIG Welding Tungsten Electrodes 2% Thoriated (Red) 1/16"x7"

10 TIG Welding Tungsten Electrodes 2% Thoriated (Red) 1/16For 110 volt welding machines. With Easy Strike igniter tip to help eliminate problems a less experienced welder might encounter while starting the arc. Easy to use for homeowners, handymen, and hobbyists. Can be positioned flat, horizontal, vertical oroverhead. Coated with titania potassium for AC, DCEP or DCEN current. 60 tensile strength.

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Aero Industry Welding


Aircraft repair and fabrication of structural components and high temperature components like exhaust systems and ducting components often calls for NADCAP approved welding.

Gas welding

A fuel gas such as acetylene or hydrogen is mixed inside a welding torch with oxygen to produce a flame with a temperature of around 6,300 degrees F. (3,482 degrees C). This flame is used to melt the materials to be welded. A filler rod is melted into the puddle of molten metal to reinforce the weld. When highly-reactive metals such as aluminum are gas welded, they must be covered with flux to exclude oxygen from the molten metal and keep oxides from forming which would decrease the strength of the weld.

Shielded Metal Arc Welding (SMAW).

This method is the most familiar and common type and is known in the trade as stick welding. A metal wire rod coated with a welding flux is clamped in an electrode holder connected to the power supply with a heavy electrical cable. The metal to be welded is also attached to the power supply. The electrical power is supplied to the work at a low voltage and high current and may be either AC or DC, depending upon the type of welding being done. An arc is struck between the rod and the work and produces heat in excess of 10,000 °F, which melts both the material and the rod. As the flux melts, it releases an inert gas which shields the molten puddle from oxygen in the air and prevents oxidation. The molten flux covers the weld and hardens to an airtight slag cover that protects the weld bead as it cools. This slag must be chipped off to examine the weld.

Gas Metal Arc Welding (GMAW).

This method of welding was formerly called Metal Inert Gas (MIG) welding and is an improvement over stick welding because an uncoated wire electrode is fed into the torch and an inert gas such as argon, helium, or carbon dioxide flows out around the wire to protect the puddle from oxygen. The power supply connects between the torch and the work, and the arc produces the intense heat needed to melt the work and the electrode. Low-voltage highcurrent DC is used almost exclusively with GMAW welding. GMAW is used more for large-volume production work than for aircraft repair.

Gas Tungsten Arc Welding (GTAW).

This is the form of electric arc welding that fills most of the needs in aircraft maintenance. It is more commonly known as Tungsten Inert Gas (TIG) welding and by the trade names of Heliarc or Heliweld. These trade names were derived from the fact that the inert gas originally used was helium.

Rather than using a consumable electrode such as is used in both of the other two methods we have discussed, the electrode in TIG welding is a tungsten rod. (In earlier procedures using this form of welding, a carbon electrode was used, but it has been replaced almost exclusively with tungsten.)

The 250+ amp arc between the electrode and the work melts the metal at 5,432 degrees F, and a filler rod is manually fed into the molten puddle. A stream of inert gas such as argon or helium flows out of the torch and envelopes the arc, thereby preventing the formation of oxides in the puddle.

The versatility of TIG welding is increased by the power supply that is used. Direct current of either polarity or alternating current may be used.

Electric-resistance welding

For aerospace welding, many thin sheet metal parts for aircraft, especially stainless steel parts, are joined by one of the forms of electric resistance welding, either spot welding or seam welding.

a. Spot Welding. Two copper electrodes are held in the jaws of the spot welding machine. and the material to be welded is clamped between them. Pressure is applied to hold the electrodes tightly together, and electrical current flows through the electrodes and the material. The resistance of the material being welded is so much higher than that of the copper electrodes that enough heat is generated to melt the metal. The pressure on the electrodes forces the molten spots in the two pieces of metal to unite, and this pressure is held after the current stops flowing long enough for the metal to solidify. Refer to MIL HDBK-5 for joint construction and strength data. The amount of current, pressure, and dwell time are all carefully controlled and matched to the type of material and the thickness to produce the correct spot welds.

b. Seam Welding. Rather than having to release the electrodes and move the material to form a series of overlapping spot welds, a seam-welding machine is used to manufacture fuel tanks and other components where a continuous weld is needed. Two copper wheels replace the bar-shaped electrodes. The metal to be welded is moved between them, and electric pulses create spots of molten metal that overlap to form the continuous seam.


Micro Resistance Welding


Welding today comes in many forms. One sector of the welding industry that is growing today as electronics and other devices shrink in size is the process of micro resistance welding. This is a thermal process where two parts to be joined are heated to the melting point and melted together, thus forming one body when the weld point cools. This process is similar to other types of thermal welding, but with several differences. The first of these differences is of course the size of the parts and components involved. Micro resistance welders are small units consisting of the welder itself which is a box with the electronics and controls for controlling the process, and the weld head which holds the micro electrodes and brings them into contact with the parts to be welded. The micro electrodes themselves are very small, often having tips, or contact points, as small as .010 of an inch square. The welders have very precision electrical current control and the heads have very precise force control to avoid breaking the fragile electrodes.

The three opposing electrode types of micro resistance welding include a straight-through, seam and projection welds. In a straight-through the electrodes are opposite each other on either side of the materials to be welded, and electrical current passes through the materials heating them at the intersection point, forming a weld. A seam weld is actually the same as the straight-through weld except that either the electrodes or the work-pieces are moved along to form a continuous series of overlapping spots. A projection weld derives its name from the fact that projections extend from one of the two surfaces. This technique is used for a number of reasons, such as decreasing the amount of energy required to make a weld, improving the heat balance when a thin piece is welded to a large piece, and to allow several welds to be made with one welding pulse.

The next two forms of micro resistance welding fall under the general heading of parallel gap welding. With this type of weld both electrodes approach the work-piece from the same direction. These techniques are especially useful where the opposite side of one of the pieces being welded has an insulated layer. The electrode arrangement in a series configuration allows weld current to flow down one electrode, through both materials and up the other electrode. With the step weld, one electrode touches each material and the current all flows across the material interface.

The first step to perform a micro resistance weld is to place the two parts on top of each other above a copper electrode. Then the weld head brings a top electrode down onto the point of weld, compression the two pieces together. With the two pieces squeezed together, electrical current is passed through the electrodes and the part at the point of intersection. The material heats rapidly, melting both pieces where they contact between the two electrodes. When the current is turned off, the molten zone cools and solidifies, forming a weld between the two pieces.

Micro resistance welding has many applications spanning nearly all areas of manufacturing, including automotive systems, aerospace, medical devices, and electronics. Micro resistance is used extensively in the electronics industry for welding small wires to other parts such as PCB pads. This type of welding is used in producing sensors, lights, battery packs, solar cells and smoke detectors, to name a few. In the automotive field micro resistance welding is used for lighting assemblies, airbag systems, electronic sensors, and ignition controls.

In conclusion, micro resistance is a popular option for joining small parts. It is low cost, clean, safe, and fast. These advantages make micro resistance welding a growing industry today.


Hobart 195195 No. 2 Stick Cable Set, 50-Foot

Hobart 195195 No. 2 Stick Cable Set, 50-FootThis Hobart premium welding cable set includes one 50-ft. ground cable with 300 Amp ground clamp; and one 50-ft. electrode cable assembly with 200 Amp electrode holder. Both cables include 1/2in. eyelet lugs crimped on for easy connection to welder/generators with 1/2in. stud connections. U.S.A.

Welding Electrodes Price: $249.99


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Sunday, September 25, 2011

US Forge Welding Electrode E7018 1/8-Inch by 14-Inch 5-Pound Box #51883

US Forge Welding Electrode E7018 1/8-Inch by 14-Inch 5-Pound Box #51883Offers ease-of-use weldability and forgiving qualities that occasional welders need. Each rod is printed with its AWS classification for easy identification. Low hydrogen mild steel. Can be positioned flat, horizontal, vertical or overhead. Coated with iron powder low hydrogen for AC or DCEP current. 70 tensile strength.

Welding Electrodes Price: $17.79


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Guidelines For MIG Welding Aluminum


MIG welding is a kind of arc welding that uses a metal electrode to match the alloy of the work section and an inert gas to transfer oxygen from the weld region. MIG welding is the most suitable welding technique for aluminum, with the exception of particularly thin aluminum sheeting.

MIG welding is a kind of arc welding that uses a metal electrode to match the alloy of the work section and an inert gas to transfer oxygen from the weld region. MIG welding is the most suitable welding technique for aluminum, with the exception of particularly thin aluminum sheeting. MIG welding aluminum needs more practice and skill than welding steel.

Prepare the surfaces of the aluminum elements by cleaning the exterior with a solvent, then using the wire brush to remove any oxides. This removes any constituent part and impurities and prevents them from becoming trapped in the weld.

Clutch the electrode at a 10- to 15-degree angle from the vertical, sharp toward the way of the weld. It is significant to use the push process when MIG welding aluminum. The pull process would prevent the argon gas from sufficiently covering the weld, resulting in an inconsistent weld.

Make a pool of molten aluminum with the electrode and gradually push the electrode forward. Regulate the voltage of the welding machine to get spray transfer of the aluminum electrode. In spray transfer, the electrode release small droplets of the metal into the weld. This will results in a smooth weld and the droplets do not get in the way with the electrode arc.

Adjust the movement speed of the electrode as the aluminum work part heats up to retain a consistent weld width. If a big fillet weld is requisite, make several thin passes as different to one thick pass, which has the potential to burn through the material.


Specification for Nickel and Nickel Alloy Covered Welding Electrodes

Offers ease-of-use weldability and forgiving qualities that occasional welders need. Each rod is printed with its AWS classification for easy identification. Low hydrogen mild steel. Can be positioned flat, horizontal, vertical or overhead. Coated with iron powder low hydrogen for AC or DCEP current. 70 tensile strength.

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Resistance-Spot Welding - Basic Application Setup


Resistance welding comes in many forms. Spot, seam, and projection are commonly used resistance weld processes. This article is going to focus on spot welding.

If you are concerned with a consistent quality of spot welding production then you need to understand that the three key principles are the time, the electrical current, and the pressure (electrode force - mechanical pressure). These three factors are closely related and need to be balanced in order for the operator to produce a quality bond between two pieces of metal with consistency. Electrodes conduct the current to the two pieces of metal to be fused as they are forged together.

The weld cycle must first build an adequate amount of heat through the electrical current and the time the current is applied to raise a small volume of molten metal from the work pieces to be bond. This molten metal is then allowed to cool while under the pressure of the electrodes until it has set at the maximum strength that the metal will allow to hold the parts together. This is referred to as the hold time on the welder.

If one of these parameters is changed without the proper adjustments to another, it may result in a poor bond.

Example: If the current is increased without an adequate amount of pressure it will result in an excessive weld splash. Conversely, a change in pressure without the corresponding changes in time and current may result in poor welds also.

The kva ratings of resistance welders are greatly impacted by various aspects of the machine set-up. When a part is very large and cannot be fit into a short set of spot welder arms - the arms may have to be extended or changed in order to accommodate the depth of the part. A spot weld weld machine with long arms for a deep entry of a product to be bonded will have a much greater electrical impedance than the same machine kva with a short set of arms. The resistance welder efficiency is greatly reduced by the electrical impedance.

Electrical impedance is the measure of the opposition that an electrical circuit presents to the passage of a current when a voltage is applied. In terms of resistance welding it is the increased resistance due to the greater distance and obstacles that the current needs to flow through to get to its destination (the welding electrodes).


Welding Tools - All You Need to Know


Tools are specifically used for some purpose to achieve or produce something and the welders need a proper tool to acquire a good control over the work.

Due to advancement in technology, products with portable and comfortable sizes are available and it enables the welders to the metals soon. To become a good welder or to become a famous entrepreneur in welding industry, knowledge about the welding tools is must. There are different types of such as mig, tig, stick and submerged arc, and each type of welding use different welding tools. Each type of welding uses different tools, so it is always better to have equipment that best suits and do all kinds of work.

From the decade, welding has been developed a lot with new welding technologies and with advanced welding equipment and systems. The welders should be aware of the latest welding technology and should be equipped with welding accessories and tools. Also, the welding industry should be equipped with modern tools such as welding electrodes, welding torches, welding consumables and welding guns and should follow the proper welding system with appropriate welding technology. The basic tool the welder use is a welding gun, it is a tool that does spot weld, tack weld and burns holes in metals and you can drill faster and make a spot within a second.

Welding torch is used to weld metals and the cutting torch is used to cut metals, rose-bud torch is used to heat metals for bending and straightening and injector torch is used to mix the two gases. If you are a tig welder, then know about the tig welder machines that is focused on user convenience and it exists in different types such as power tig 200DX, 250EX, 315DX, 225LX and power 1-tig 200. They are designed to weld any types of steel and stainless materials and it is easy to repair in the field and garage. Power arc welder exists in two types such as 200 welders and 160 welders. Smooth dc arc, low power consumption, high duty cycle with digital display and adaptive arc force control are its special features.

Mig welder exists in four types such as 160 welder, 200 welder, 205 welder and 250 p welder. They are Convenient and portable, with the help of this unit, you can go any where to get to the repair. Multi process units are completely redesigned for greater portability and convenience, the power ultra is ideal for using in the field for the spot repairs and quick fab jobs requiring basic tig, stick and/ or plasma processes. These units exists in six types such as powerultra 164, 185, 205 and powerpro 205, 226 and 256. The process of welding cannot be successful unless there are no proper accessories and parts. Accessories such as guns and torches, spool guns, welding helmets and gloves, welding carts and parts are important accessories in welding.


Hobart 7014 Stick, 1/8-Inch

This Hobart premium welding cable set includes one 50-ft. ground cable with 300 Amp ground clamp; and one 50-ft. electrode cable assembly with 200 Amp electrode holder. Both cables include 1/2in. eyelet lugs crimped on for easy connection to welder/generators with 1/2in. stud connections. U.S.A.

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Saturday, September 24, 2011

Aspects of the new monel and nickel arc-welding electrodes (Mond Nickel Co., Ltd. Publications)

Offers ease-of-use weldability and forgiving qualities that occasional welders need. Each rod is printed with its AWS classification for easy identification. For deep penetration of dirty and oil soaked material. Can be positioned flat, horizontal, vertical or overhead. Coated with cellulose potassium for AC or DCEP current. 60 CD tensile strength.

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Learn to Weld DVDs - A Good Source of Welding Techniques


Instructional DVD sets are very similar to the online classes. While you learn at your own comfort and convenience, you can get many welding related information from these learn to weld DVDs. You just need to do some simple steps. Put the DVD in and watch each portion of these training programs as many times you want. The best thing you can do is follow the procedure and practice as you learn. The best benefit of these DVDs is that you will be able to learn specialized welding techniques from a DVD quite similar to a in person training. The welding DVDs are the cheapest way to learn welding skills than any other mode of training. As the specialized welding skills are some of the highly paid ones, your minimal investment will never go unproductive.

Benefits of learn to weld DVDs:

Most of these learn to weld DVDs are available in the market at a very realistic price. In addition to that it includes many features and topics which are outlined below.

• A detail list of all safety equipment needed for welding

• An overview about types of welding electrodes and how to use them

• Instructions to prepare the materials for welding

• How to use the Premier Power Welder to "Arc Weld"

• Information about connecting and controlling the welding current

• Different welding positions

• How to strike an arc in an easiest way

• Several weld bead patterns

• Suggestion and helpful tips for better welding

• All about overhead and vertical welding

• All types of welding process including MIG and TIG

• How to use field repair techniques

• How to recharge a battery in a minimal time

• Usage guide of the 115V DC power outlet as a power tools

Practically, these learn to weld DVDs are worth to invest on. They are a good source of knowledge, give you the comfort you are looking for and the least expensive mode of training process. Hence it is time to for you to take another step towards your goal.


The Portable Rod Oven: An Indispensable Welding Tool


The portable rod oven is an indispensable welding tool to have while on the welding job. As one of the many welding accessories available to welders, the welding rod oven - also referred to as an electrode oven, hot box or welding electrode stabilizing oven - has been refined and redesigned over the years in order to accommodate welders that operate in a variety of challenging environments.

The portable range of rod ovens seeks to provide the welder a convenient means to maintain electrodes at optimum temperatures where the welding job may take them.

The portable rod holding oven is used all over the world for welding projects. This highly important tool comes in a variety of shapes and sizes. From round cylindrical shapes which stand upright, to rectangular models shaped like tool boxes, these valuable tools have been designed in many different ways to enhance the portability for welders.

The trend in welding rod oven design has been to increase the light weight nature of the product so that the user is not burdened with a heavy, cumbersome tool that is difficult to operate and bring to the field. Most rod ovens are made of painted steel and treated with a chemical resistant finish to protect against damage from chemicals and exposure to the elements.

For welder testing and approval, some states even require that a rod oven be used on site at all times for all low-hydrogen welding jobs. This demonstrates the importance of the rod oven as a welding tool in today's industry. Many problems can result in the weld if improper welding rod storage procedures are not followed on site such as porosity, hydrogen embrittlement and cracking.

Proper welding rod maintenance is absolutely essential in welding and should not be overlooked. Opened, low-hydrogen welding rod containers are unfortunately a familiar sight at welding jobs, with many welders not paying attention to the ramifications of improper storage. This can lead to many problems down the road, possibly costing many thousands of dollars in repair work and time.


Stick Welding Tips and Basics


If you want to learn stick welding it will take practice and a little patience to learn to do it in a way that will produce fine welds. This is an important thing to remember although some people may say they never had to practice much.

Stick welding is one of the basic methods of welding that many students learn as they are just beginning to learn welding. This is also a method of welding that is high in demand because people need this help whether they are working iron, pie, boilers or building ships.

You will find that you will need the skills of all types of positions including flat and horizontal and ventricle or overhead welding. All of these will take some time to learn and some will be more challenging than others.

Here are some tips to help you make a better weld:

1. The right electrode for the job -- many people aren't sure of the size of the electrode they should use and this is important to know. The size of the electrode will depend on the situation you are welding within. In this situation you will be fighting against gravity if you are doing the weld vertically so you will want to use an electrode that is AWS classified as 7018 because they are low in their powder content.

2. A weld shelf makes a good guide -- if you are doing vertical or horizontal welding you will need something that the electrode can follow so you don't loose any of it to gravity. You can do this by creating a serious of little shelves so you can do a section at a time so that you can continue to work above a weld that you have already laid. This will create a situation where one puddle will freeze in time to hold the next weld.

3. Don't undercut if possible -- this can happen because you have to weave the electrode and sometimes your work may be gouged and not have enough fill metal. When this occurs, you will be working against gravity because it will work to pull your fill metal away from the space you are working. You can reduce your puddle size to help you have more control in this situation.

4. Stay away from weird sizes for your metal -- most metal will come in specific sizes that are always common. These metals will be easier to find and you can weld them fester. Stick with the ones that are AISI-SAE 1015 to 1025 so that you can be sure that you have what you need.

5. Make sure you know your arc length -- a good rule of thumb is to use an arc length that is the same distance from the metal as your electrode's thickness. As an example, if you have an electrode that is ¼" thick, then have your arc ¼" thick. Also remember that as you use the electrode, you will have to move it closer to the metal.

These tips will help you develop a more even weld and keep things more controlled.


Campbell Hausfeld WS0970 115-Volt 70 Amp Arc Stick Welder

Campbell Hausfeld WS0970 115-Volt 70 Amp Arc Stick WelderThe Campbell Hausfeld WS0970 115-volt 70 Amp arc stick welder can weld mild or stainless steel from 18-gauge to 1/8-inch thick, and is ideal for use on boat trailers, wrought iron, or automotive sheet metal. It comes with a dual heat setting for use with welding rods, and its thermal overload protection automatically shuts off the welder at its duty cycle rating. A contoured face makes operating the arc welder easy, as do the carry handle and storage clips to hold the cables in place. The Campbell Hausfeld WS0970 welder is powered by a 115-volt current and generates 70 Amps of power. A built-in storage keeps accessories organized while cord management maintains secure storage. This welder includes a welding shield, hammer/brush, electrodes, and quick start guide. Campbell Hausfeld backs its welder with a 5-year limited warranty.

What's in the Box
Welder, welding shield, hammer/brush, electrodes, and quick start guide.

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The Basics of TIG Welding Current Types and Polarity Settings


To begin TIG welding machines are designed to produce a constant amperage at all times and that means when you set the machine it is set in terms of amperage settings. The amperage output while welding rarely changes. What does change is the voltage depending on the length of the arc. The arc is how the voltage is regulated. The voltage will increase when the arc length is increased and at the same time the voltage will decrease when the arc is shortened. Ultimately a TIG welding power supply will always stay consistent on the amperage setting!

TIG welders produce two types of current. They are D/C or direct current and A/C or alternating current. Alternating current is typically used for welding aluminum and magnesium. Outside of these two metals A/C is rarely used. D/C or direct current is used on most other metals. This includes steel, stainless steel, copper, copper nickel, and most of the exotic metals.

Direct current has two polarity types. The two polarities are DCEN or direct current electrode negative and DCEP or direct current electrode positive. What electrode (-) negative means is the TIG torch is the (-) negative side of the circuit or terminal. On the electrode (+) positive side it means the TIG torch is the positive side of the circuit or terminal. Direct current is the same current type that a car battery produces. The way D/C works is the electricity flows in one direction only. That is it flows from the (-) negative side to the (+) positive side. Just remember the (-) negative side is the losing side and the (+) positive side is the gaining side.

The way direct current polarity applies to TIG welding is how much heat is concentrated on the tungsten electrode. If the machine is set on DCEN or direct current electrode negative 2/3 of the heat is concentrated on the weld joint. DCEN is also one of the reasons tungsten is able to produce such a high temperature arc without melting! On DCEP or direct current electrode positive 2/3 of the heat is concentrated on the tungsten electrode.

The way this applies to TIG welding depends on the thickness of the metal welded. Most of the welding done with TIG is on DCEN because the metal is on the thicker side. Here you want the majority of the heat to be on the metal welded. For most welding applications just remember that you want the TIG torch to be the (-) negative side of the circuit. When it comes to welding very thin sheet metal you may want to consider switching over to DCEP or direct current electrode positive (+). This will put most of the heat onto the tungsten electrode and keep the arc from burning up the sheet metal. In the case of DCEP you want to weld using low amperage setting otherwise the tungsten will also burn up! There is one other case you would want to set the machine to DCEP and that is to shape the tungsten into a ball end. DCEP will start to melt tungsten very quickly on this setting and that is why it is used to create ball shaped tungsten ends.


Friday, September 23, 2011

Lincoln Electric: How To Use Combination Wire Feed Welders Part K550-5 [Dual English/Spanish/French]

Lincoln Electric: How To Use Combination Wire Feed Welders Part K550-5 [Dual English/Spanish/French]Instructions are given in English, Spanish and French on how to use combination wire feed welders. Lincoln Electric - The Welding Experts® - It's more than a slogan it's a reference to the knowledge we've gained in over 100 years as a leader in the welding industry. And now the lessons we've learned are here, at your finger tips.

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US Forge Welding Gas Welding Rods Flux Coated Low Fuming Bronze Brazing Rod 1/8-Inch by 18-Inch .8-Pound #02232

US Forge Welding Gas Welding Rods Flux Coated Low Fuming Bronze Brazing Rod 1/8-Inch by 18-Inch .8-Pound #02232General-purpose for steel and copper alloys. No flux required.

Welding Electrodes Price: $18.99


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Lincoln Electric Stick Electrode Welding Guide - 1979 (M600)

Instructions are given in English, Spanish and French on how to use combination wire feed welders. Lincoln Electric - The Welding Experts® - It's more than a slogan it's a reference to the knowledge we've gained in over 100 years as a leader in the welding industry. And now the lessons we've learned are here, at your finger tips.

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Arc Welding Process in a Nutshell


There has been an increase in the affordability and availability of arc welders that most of the people have a welder of their own. Many hobbyists also own portable arc welders. Before purchasing an arc welder, you need to know the requirements and the product that best suit the needs. Basically arc welding is one of the strongest methods of joining metals. During the welding process, an electric current allows an electric arc to melt the two metal pieces. A strong and solid bond is formed when a filler material mixes with the two metals. This process is inexpensive and it may vary depending on the shielding and filler material.

It must be noted that intense heat is used in all arc welder methods. An electrode or welding wire dispenses the heat in most of the cases. Usually electrode is more preferred as it is comparatively to change them by popping them out of the electrode holders. However there are advantages with each welding processes. In shielded metal arc welding, a welding rode in an electronic holder would be used. Shielded metal arc welding is also called as stick welding and it the most common and portable arc welder. In SMAW welding, an electrode with a metal core would be used. The flux around the core melts with the pieces that you are working on and fuse the metals.

If you are planning to weld thin metals, use gas metal arc weldings (GMAW). During the gas metal arc welder process, a gaseous shield would be used around the melted metal. Generally carbon dioxide and oxygen are the common gases used in GMAW welding. Hence there is another name for the welding; metal inert gas welding or MIG welding. In gas tungsten arc weldings, you need to apply the arc between a tungsten electrode and the work pieces. Tungsten inert gas welding is otherwise known as TIG welding. One of the advantages of TIG welding is that it doesn't always require the use of a filler material.

In flux core arc welding (FCAW), the welder fuses metal together with the arc welder. This is done by directing the high temperature arc between the filler metal electrode and the metals. In plasma arc welding (PAW), the metals are heated using a plasma gas from a torch and if necessary, additional shielding gas is used. If you want to produce fusion of metals, use submerged arc welding (SAW) process by heating metals between the arc and the work piece.

During any arc weldings process, the welder should take necessary precautions and wear protective clothing. Burns that is caused by the sparks while electric current enters the metal is the most common injury for welders. So the welder should wear protective clothing particularly wool clothing for safety. The light that the electrode produces is also dangerous as it emits significant amount of radiation. So it is necessary to wear a protective shield over the faces. Large quantity of heat is also produced when current passes into the metal. This heat generates fumes that can be hazardous. So welder should wear masks for protection.


Lincoln Electric K1170 AC225S Stick Welder

Lincoln Electric K1170 AC225S Stick WelderThe Lincoln electric AC-225 compact stick welder produces an extremely smooth AC arc for welding a wide variety of materials including carbon, low alloy and stainless steels as well as cast iron. Ideal for home, farm, shop, repair and maintenance, build-up welding and light fabrication. Easy to install with attached input power cable and NEMA 6-50P plug, plus it's easy to operate: a full range 40-225 Amp selector switch quickly sets the welding current and ensures a uniform arc each and every time you weld. Smooth arc makes it easy to weld with different electrodes, including mild steel, low hydrogen, stainless steel and hardfacing electrodes. U.S.A. Volts: 230, Amps: 40 - 225, Duty Cycle: 225A / 25V / 20%, Amperage Adjustments: 40 - 225, Range Selection: 40 - 225, Weldable Metals: Carbon, low alloy, stainless steel, cast iron, Weld Thickness (in.): Up to 1/4, Electrode Size (in.): 3/32 to 5/32, Electrode Cable Length (ft.): 10, Clamp Cable Length (ft.): 10, Power Cord (ft.): 6, Dimensions L x W x H (in.): 12 x 17 1/4 x 24

Welding Electrodes Price: $577.31


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Thursday, September 22, 2011

10 TIG Welding Tungsten Electrodes 2% Thoriated (Red) 3/32"x7"

10 TIG Welding Tungsten Electrodes 2% Thoriated (Red) 3/32Offers ease-of-use weldability and forgiving qualities that occasional welders need. Each rod is printed with its AWS classification for easy identification. For deep penetration of dirty and oil soaked material. Can be positioned flat, horizontal, vertical or overhead. Coated with cellulose potassium for AC or DCEP current. 60 CD tensile strength.

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Aluminum Gas Welding Compared to Welding Steel Using the Gas Tungsten Arc Process


Aluminum gas welding can be accomplished with gas tungsten arc welding (GTAW) and it can also be used to weld steel, as well as other metals. GTAW is also called tungsten inert gas (tig) welding. Welding steel is one of the easier jobs when using rig welding, but there are a number of factors, which make it much harder to weld aluminum.

From cleanliness, arc length, machine settings, welding with a dirty tungsten electrode, filler rod angle, type of electrode, torch angle and size of electrode - you have to be extra-careful with all of these factors when you tig weld aluminum.

Here we go over these factors and how you have to be much more careful with aluminum than with steel.

- Make sure that the settings for your machine are correct. Set your machine to use alternating current and the high frequency switch should be at continuous mode otherwise it will make the arc stutter.

- A piece or object of aluminum left outside is likely to be highly oxidized after having come in contact with the elements. That should be weld only after thoroughly cleaning it - otherwise it will burn or weld extremely fast.

- Arc length - it is important to keep the arc at just the correct length. Arc lengths too long or too short, both should be avoided with aluminum. Too short the length, you your metal will jump on your electrode, damaging that and you. Too long a length and the heat will not be pinpointed enough to be of proper use.

- Keep your electrode clean. A dirty electrode will make the weld sooty - taking any fun out of the job you may have been having.

- Do not use pure tungsten electrodes with the new types of tig inverters to weld aluminum. The old types could use them, but not these new ones.

- You should keep the 1/16", 3/32" and 1/8" sized tungsten electrodes within easy reach when working with aluminum. With steel it is one size fits all policy, where you can go with a 3/32" tungsten for most of the jobs. But with aluminum, you need different electrodes depending on the thickness of the aluminum.

Aluminum gas welding just needs to be done with more care than other types of welding. Keep all these factors in mind and you will have your boat repaired or your ladder fixed in the best possible manner.


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US Forge Welding Cutting Specialty Electrode 3/32-Inch by 14-Inch 4-Pack #09921Cutting, gouging, chamfering (grove/bevel) of any metal. No special equipment or skill needed. Removes unwanted welds and prepares parts prior to welding. In easy to open, resealable small packaging for single job use. Use with arc welding machine for removing frozen bolts, auto body repair, in place of chisel or hacksaw, for cutting holes, and for cutting various materials including cast iron, steel, stainless steel, aluminum or farm equipment.

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Stick Welding Process Overview


Stick welding is a process that uses a covered electrode that is also called a stick. The full name for stick welding is Shielded Metal Arc Welding (SMAW) and is more widely used than many other methods of welding.

This works by melting the flux that covers the electrode as the welder welds a work-piece. As this process continues it forms gas and slag and these two things shield the arc and the weld pool of molten metal. After the work-piece is welded the welder must chip off the slag. The flux also adds scavengers, deoxidizers and other types of alloy elements to the metal during the weld.

There are many advantages of using this method. First of all this is one of the most inexpensive ways to weld because the equipment is easy to use, portable and inexpensive. You don't have to worry about regulating the flux because the electrode does the regulating of the flux. This method is also less susceptible to wind and drafts than other methods, especially the welding processes that are gas shielded. You can also use this method in any position.

The Stick welding process overview shows that this process is used more than any other form of arc welding. It is also versatile, flexible and used by a wider variety of individual. As an example, you can use this method to make small repairs around your home, you can repair equipment and it is used in the erection of still and other commercial types of joining metal.

Sometimes there can be problems with stick melding but they are relatively easy to fix. Some of the most common problems you may run into include:

- Spatter - this basically makes the metal look messy and it is expensive to clean. There are many things you can do to fix this and we will talk more about this in the tips article.

- Undercutting - this also changes the appearance of the metal and can weaken the weld especially when it has tension or fatigue.

- Wet Electrodes - if you see that your arc is erratic or it is acting rough, then the electrodes can be wet.

- Cracking - there are different types of cracks can happen in different spaces in the weld, and it can be caused by high carbon or high alloy content.

When you are looking for flux coated electrodes you can find them in many different sizes and lengths. The best way to tell which ones you need is to match the base metal with the properties of the electrodes. You can usually find them in bronze, aluminum bronze, nickel and stainless steel.

Of all the electrical welding methods, stick welding is the most versatile because it can be used to weld more metals together than many of the other methods. It is also one of the easiest to do though it will take practice if you are truly a beginner to welding. However, even when you are a beginner it is quick to learn and with practice you will do a very good weld using this method.


ISO 12145:1998, Resistance welding equipment - Angles for mounting spot welding electrodes

ISO 12145:1998, Resistance welding equipment - Angles for mounting spot welding electrodesThis International Standard specifies angles for angular adjustment of electrode caps, adaptors and point adaptors.The angles are applicable when straight fixed electrodes cannot be used to obtain the correct position for welding a single spot.For examples of application see figure 1. This title may contain less than 24 pages of technical content.

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How to Weld Steel


When learning how to weld steel we first need to determine both the type of steel to be welded and the thickness of the steel. Basic steel is typically mild steel that is used for most structural purposes and various other applications such as automotive bodies, chassis building and many types of appliances.

Stainless steel on the other hand comprises of different compositions of metals and requires specialized equipment for welding. A good test to differentiate mild steel from stainless steel is to try and attach a magnet to the metal. Stainless steel is not magnetic where as mild steel is.

There are four different types of welding techniques that can be used when learning how to weld steel and are as follows.

Gas welding.

Gas or oxy-acetylene welding is seldom used to weld steel these days. The process requires that the two metals to be welded are heated and fused together generally with the aid of a filler roe also made of steel. Best used for light metals and sheet metals.

Arc or stick welding.

Ideal for home use or maintenance. Arc welders can weld metals starting at 1/8th (3mm) inch thick up to 1 inch (25mm) thick. While the process. Thinner metals can be welded however it does require more skill. Stick welders use flux coated electrodes that are used to generate the electric arc or heat source and act as the filler material to fuse the steel.

Mig welding

Mig welding is the easiest way how to weld steel. Mig welders operate in a similar way to arc welders except the electrode is in the form of a continuous wire feed allowing the operator to work for long periods without the need to change the wire. The welding wire is contained on a spool that comes in various sizes depending on the machine.

Mig welders also use a shielding gas to prevent contamination at the weld area. With arc welders this is similar in a sense to the flux coating on a welding electrode. The need for shielding gas does limit a mig welder as to the portability of the machine and is not very useful if welding in a stiff wind as the gas gets blown away. There is now however a flux cored welding wire for mig use that removes the need for shielding gas.

Mig welders can be used on most any thickness of steel depending upon the power of the machine. They are ideal to learn how to weld with and excellent for welding thin steel as on automotive bodywork.

Tig Welding.

Tig welding is a specialised process that requires great skill by the operator. Ideal for sheet metal work where precise and pure welds are required.

While learning how to weld steel is quite an easy process, the basics of welding need to be learned from both a practical and a theoretical point to get things right from the beginning. Many hours can be wasted through trial and error welding where some simple tuition can get you welding very well in a short period of time.


Wednesday, September 21, 2011

The 2006-2011 World Outlook for Hard-Facing Metal Arc Welding Stick Electrodes

The 2006-2011 World Outlook for Hard-Facing Metal Arc Welding Stick ElectrodesWHAT IS LATENT DEMAND AND THE P.I.E.?

The concept of latent demand is rather subtle. The term latent typically refers to something that is dormant, not observable, or not yet realized. Demand is the notion of an economic quantity that a target population or market requires under different assumptions of price, quality, and distribution, among other factors. Latent demand, therefore, is commonly defined by economists as the industry earnings of a market when that market becomes accessible and attractive to serve by competing firms. It is a measure, therefore, of potential industry earnings (P.I.E.) or total revenues (not profit) if a market is served in an efficient manner. It is typically expressed as the total revenues potentially extracted by firms. The “market” is defined at a given level in the value chain. There can be latent demand at the retail level, at the wholesale level, the manufacturing level, and the raw materials level (the P.I.E. of higher levels of the value chain being always smaller than the P.I.E. of levels at lower levels of the same value chain, assuming all levels maintain minimum profitability).

The latent demand for hard-facing metal arc welding stick electrodes is not actual or historic sales. Nor is latent demand future sales. In fact, latent demand can be lower either lower or higher than actual sales if a market is inefficient (i.e., not representative of relatively competitive levels). Inefficiencies arise from a number of factors, including the lack of international openness, cultural barriers to consumption, regulations, and cartel-like behavior on the part of firms. In general, however, latent demand is typically larger than actual sales in a country market.

For reasons discussed later, this report does not consider the notion of “unit quantities”, only total latent revenues (i.e., a calculation of price times quantity is never made, though one is implied). The units used in this repor

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ISO 18276:2005, Welding consumables - Tubular cored electrodes for gas-shielded and non-gas-shielded metal arc welding of high-strength steels - Classification

ISO 18276:2005, Welding consumables - Tubular cored electrodes for gas-shielded and non-gas-shielded metal arc welding of high-strength steels - ClassificationISO 18276:2005 specifies requirements for classification of tubular cored electrodes with or without a gas shield for metal arc welding of high-strength steels in the as-welded condition or in the post-weld heat-treated condition with a minimum yield strength higher than 550 MPa or a minimum tensile strength higher than 590 MPa. One tubular cored electrode can be tested and classified with different shielding gases, if used with more than one.This document is a combined specification providing classification utilizing a system based upon the yield strength and an average impact energy of 47 J of the all-weld metal, or utilizing a system based upon the tensile strength and an average impact energy of 27 J of the all-weld metal.

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Welding Services Use Different Types of Electrodes for Optimum Performance


Welding involves situations that require extreme heat and the electrodes play a very important role in such situations. Well, there are different types of welding electrodes available in the market and professionals have reasons to choose anyone. Some of the well known types of electrodes are metal core, solid core and flux core. Though the availability of all these types has increased manifold, the flux core arc welding coupled with the gas metal arc welding are the professionals' favorites for steel. Basically, different types of steel require different types of electrodes to ensure optimum outcome.

Therefore, when someone is choosing the electrode, he or she must consider the type of steel to be welded for the purpose. In this regard, one must consider the mechanical properties, chemical compositions, as well as the microstructure of the steel. The methods of processing the steel also play an important role in choosing the electrode. Now, it is easy to understand why choosing the ideal electrode should be left to the professionals.

Even if you have managed to choose the somewhat right electrode for welding, there are some other and even more complicated challenges lying ahead. Basically, you need two equipments required for welding - the electrode and metal for welding. You have to make sure that both of them are complementing the base metal that you are welding. At the same time, the electrode must not offer the exact chemical composition metal match as it may cause rust erosion. Ideally, you should be using an electrode that will have around.02 to.04 percent less carbon than the metal to be welded. However, make sure that you are using suitable metals to compensate this lack of carbon count by choosing appropriate alloy.

Remember, it is very important that the electrode you are using is capable of giving sufficient tensile strength and impact resistance to the metal. In this regard, overmatching is very important. Make sure you are not using additional metal to overmatch as that may give more strength to the deposited metal than the weld metal.

If you are trying to do it yourself, you need to do some study on electrode. Go for the AWS guide to size and numbering system. This is very important in understanding the proper application of the electrodes. However, the good thing is that the electrodes have clear labels and codes so that you can go through them easily. Anyways, it is best to hire professional welding services to ensure that you get the optimum result with welding.


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How to Select and Prepare Tungsten Electrodes For Your Application


To those of us who may not be aware, tungsten is an uncommon metallic element that is used in the manufacturing of TIG (or GTAW) electrodes. The TIG electrodes demand the type of hardness and high temperature resistance that tungsten alone can provide. This is because tungsten electrodes are meant to carry the welding current to the arc. It is to be noted that tungsten has an inconceivably high melting point when compared with other metals.

These electrodes come in different sizes and lengths and are available either as pure tungsten or a hybrid of tungsten mixed with other rare earth elements and oxides. Choosing the right electrode depends on the type and thickness of the base material and whether you are going to weld with alternating or direct current.

Please know that pure tungsten electrodes are expected to contain nearly 100% tungsten and have the maximum consumption rate of all electrodes. Tungsten electrodes are strangely less costly than its alloyed counterparts. These electrodes form a balled tip when heated and provide great arc stability for AC welding with balanced wave. Pure tungsten also provides good arc stability for AC sine wave welding - for aluminum and magnesium welding.

Thoriated tungsten electrodes (Color Code: Red) contain a minimum of 97.30% tungsten and balance thorium. These electrodes are the most widely used electrodes and are known for longevity and easy use. Thorium is highly useful in increasing the electron emission qualities of the electrode. Thus, it improves arc starts and enables a higher current carrying capacity. It also results in a lower level of weld contamination than other electrodes.

Ceriated tungsten electrodes (Color Code: Orange) contain a minimum of 97.30% tungsten and balance cerium. These electrodes are known to perform remarkably well in DC welding at low current settings. With its excellent arc starts at low amperages, ceriated tungsten are widely used as orbital tube and pipe manufacturing, thin sheet metal work or jobs where small and delicate parts are welded.

Lanthanated tungsten electrodes (Color Code: Gold) contain a minimum of 97.80% tungsten and balance lanthanum. These electrodes are known for their excellent arc starting as well as arc stability, low-burn-off rate and quick re-ignition capabilities. The fact is, in select cases, lanthanated tungsten electrodes can replace 2% thoriated without having to make significant welding program changes.

Zirconiated tungsten electrodes (Color Code: Brown) contain a minimum of 99.10% tungsten and balance zirconium. Zirconiated tungsten electrode is capable of stable arc and it resists tungsten spitting. The added feature is its current carrying capability which is equal if not more than thoriated tungsten. Zirconiated electrodes are unsuited for DC welding.

Rare earth tungsten electrodes (Color Code: Gray) contain unspecified additions of rare earth oxides or a mixture of different oxides. However, manufacturers will indicate each additive and its percentage on the outer label. Depending on the additives, you can obtain a stable arc in both AC and DC processes as also more longevity.

Finally, it may be said that the arc quality and welding performance you achieve will largely depend on the type and shape of tungsten you use. Each of these six types of tungsten has its own merits and shortcomings. It is therefore critically important you choose the right tungsten appropriate for each application.


What Is The Difference Between A MIG Weld And A TIG Weld?


A MIG welder and a TIG welder can be used during welding, which is the process involving the fusing together of metals by melting the metal where they meet and will be joined. In many cases, pressure and / or filler material is used to aid in the fusion process.

Both MIG and TIG welds are types of arc welding, which utilizes the concentrated heat of an electric arc to join together metals by fusion of the parent metal by a consumable electrode. Depending on the material to be welded and the electrode used, the process utilizes either direct or alternating current for the welding arc.

The MIG weld process, or Metal Inert Gas weld, fuses the metal by heating with an arc. With this type of weld, the arc is placed between the filler metal electrode and the work piece. Shielding is provided by outwardly supplied gas or gas mixtures. A TIG weld or Tungsten Inert Gas, on the other hand, functions by joining metals through the process of heating with tungsten electrodes that do not become part of the completed weld. The process utilizes argon or other inert gas mixtures as shielding and filler metals are rarely used.

Some of the basic differences between the two types of welds are that MIG welding is faster than using TIG welding, as utilizing TIG welding requires more skill that MIG welding. A solid wire is used in the MIG Flux Cored Arc Welding-Gas Shield (FCAW-G) while TIG uses a flux cored electrode.

Another obvious difference is that TIG uses Tungsten to carry the arc, and a user of a TIG welder needs to have sufficient experience in the craft of welding. A MIG weld user, meanwhile, can carry on working despite being a novice welder.

Overall, while both MIG and TIG are gas shielded arc welding processes, the primary difference lies in the way the filler metal is added to produce the weld. With the TIG process, the arc is created between a tungsten electrode mounted in a hand-held torch and the work piece to be welded. The welder initiates the arc by means of a switch. The filler metal, in the form of a hand held rod, is then added to the weld puddle by the welder as the torch is manipulated along the joint which is to be welded. The MIG process uses a filler metal which is the electrode and the arc is created when the filler metal comes into contact with the work surface.


Tuesday, September 20, 2011

Welding Aluminum Using GTAW Aka the Gas Tungsten Arc Process - Compared to Welding Steel


Welding aluminum is harder than welding steel. Why? Because everything that can go wrong on steel is magnified times 10  when you are Tig welding aluminum.

Cleanliness, machine settings, arc length, welding with a dirty  tungsten electrode, torch angle, filler rod angle, type of electrode, and size of electrode . You name it, When you weld aluminum, its just more important to get all these things right,


If the aluminum you are welding has been left outside, like a boat dock ladder, or aluminum boat propeller, it is most likely heavily oxidized. It needs to be cleaned or it will weld like Fido's butt.
The machine settings have to be right too. Alternating current is the name of the game for tig welding aluminum and the  high frequency switch  needs to be on continuous...otherwise the arc will stutter.
Amperage is usually controlled with the foot pedal and with steel, you dont have to continually adjust amperage. At least not much. But since aluminum is such a good heat conductor, your foot pedal amperage control will get a workout. (Some tig welders even use the foot pedal to pulse the amperage to overcome heat buildup and to get the stack of dimes look.)

Arc length is important on steel, but on aluminum it is even more critical, too long an arc length and the heat will not be pinpointed enough casing your rod to ball up and contaminate, too short an arc length and metal will seem to jump on your electrode causing you to cuss like a sailor.
With steel, sometimes you can get away with a slightly dirty electrode... no big deal. But on aluminum, a dirty tungsten takes all the fun out of welding.  The weld will be sooty and will prompt your buddies to make fun of you.
Too much torch angle will cause the heat to melt the tip of your filler rod and the  filler wire will blob into the puddle,. This happens on steel too, just not as bad.
Type of tungsten electrode matters a lot too, especially if you are welding with a newer inverter type tig welder.  Old timers used to insist on using pure tungsten for tig welding aluminum. With the new tig inverters, using pure tungsten to weld aluminum will make you ask for a refund on your welding machine.
And what about the size of your tungsten electrode? With steel, it is possible to use a 3/32" tungsten for almost everything except razor blades. With aluminum, you need to use the right size electrode for different thickness metal. You really need to keep some 1/16", 3/32", and 1/8" tungsten handy and be willing to change electrodes when the  job calls for it...and sometimes even in the middle of doing the same job.

Do you get the picture yet? Welding aluminum is just plain harder because everything matters more.


How to Stick Weld Traveling Vertical Down 101


To start Stick welding vertical down you need the right electrode. The ideal electrodes for this position are electrodes that don't have a heavy flux coating. The three electrodes that come to mind are:


E6010
E6011
E6013
The reason for using an electrode that is light on the flux coating has to do with how the slag is formed on the weld puddle. For example an E6010 has less than half the flux coating of an E7018 electrode. When you are actually welding in the vertical down position the flux will want to go ahead of the puddle. This is why you want an electrode that is light on the flux in this position! If the flux or slag gets ahead of the puddle three things are likely to happen. First the electrode will stick, the second is slag inclusions, and finally the weld will not penetrate properly. None of these results is good for the weld.

Ideally welding vertical down is something you do on thinner metals. This is not a technique commonly used for heaver weld joints with one exception. That is pipe line welders typically weld vertical down and any other time it is for thinner metals.

Welding vertical down is done by using a mid range amperage setting and the travel speed is fast. Once you start your arc you need to establish a puddle. After that it is either just a straight down motion or a slight side to side weave. Just remember to stay ahead of the puddle to avoid sticking the rod, slag inclusions, and lack of penetration. That is all there is to Stick welding vertical down and it is one of the easier positions to learn how to weld!


Hobart 770476 7018 Stick, 3/32-10lbs

Hobart 770476 7018 Stick, 3/32-10lbsHobart welding rod features low-hydrogen electrodes for use in all positions on low-, medium- or high carbon steels. Weight (lbs.): 10, Wire Material: Low-hydrogen electrode, Tensile Yield (PSI): 70,000, Diameter (in.): 3/32

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BPVC-IIC - 2007 BPVC Section II - Materials Part C - Specifications for Welding Rods Electrodes and Filler Metals

BPVC-IIC - 2007 BPVC Section II - Materials Part C - Specifications for Welding Rods Electrodes and Filler MetalsThis is a service book to the other Code Sections providing material specifications for the manufacture, acceptability, chemical composition, mechanical usability, surfacing, testing requirements and procedures, operating characteristics, and intended uses for welding rods, electrodes and filler metals. These specifications are designated by SFA numbers and are derived from AWS specifications.

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The Financial Advantages of MIG Welding for High Production Fabrication


Chances are if your business is involved in manufacturing metal products or does custom metal fabrication then you are always looking for more efficient ways of increasing production. In this article you will discovered the financial advantages of MIG welding and why is may be the best process for your businesses, shop or manufacturing plant.

What is MIG Welding?

MIG welding is a semi-automated welding process that allows the welder to use their discretion as to when and where to weld while the machine continually keeps feeding a welding electrode to the weld joint. This process is technically called Gas Metal Arc Welding or GMAW but most people today have accepted the term "MIG Welding".

Advantages for Production Welding

MIG has many advantages over other processes for production welding. Some of the advantages may not seem to be much but over time they will save your company money in material cost and labor. Some of the advantages are:


Fast welds
Joins almost any metal
Requires very little cleaning

This process produces fast weld when compared to Stick or TIG welding. The production speed is excellent because MIG welders use a spool of wire that continually feeds the electrode to the joint. This saves time and money on electrode replacement down time while keeping stub waste to the bare minimum. The electrodes come is spools as small as 1 lb that are made for small production runs and cab be as large as 100lbs or more. This keeps production flowing without many interruptions for electrode replacement. MIG also allows welding of different metal thicknesses with a single diameter electrode. This is where production can be increased based on the machine settings. The electrode speeds are regulated in IPM or inches per minute and that means that production rates can increase based on machine settings.

MIG welding is a process that can weld almost any metal out there. The weld quality is excellent compared to most other types of processes with the ability to weld different metal thicknesses with a single diameter electrode. Some of the metals that it can weld are:


Carbon Steel
Stainless Steel
Aluminum
Nickel Alloys
Copper
Titanium

Another benefit of MIG welding is that the welds are clean and there is not much slag to clean (if any). The electrodes use a shielding gas to keep the atmosphere out of the weld area and that translates to saving time and labor costs on cleaning welds. Unlike Stick or Flux cored arc welding there is no flux on the electrode that requires the weld to be cleaned and dressed. The most cleaning that may be required can be done with a wire wheel.

In the end MIG welding is a great welding process for companies that need fast, clean, quality and low cost welds for their production needs.


How Electrodes Are Used in Many Industrial Applications


Electrodes are conductors through which an electric current enters or leaves a material, substance or a vacuum whose electrical characteristics are being measured, used or manipulated. Terminal points in electrical components such as transistors, diodes and batteries are all common examples of an electrode with which most people will be immediately familiar.

In an electrochemical cell, these terminal points are referred to as either anodes or cathodes - the anode is the point at which electrons leave the cell and oxidation occurs. The cathode is the point at which electrons enter the cell and reduction occurs. Each of these points may become either the anode or the cathode depending on how the voltage applied to the cell. Bipolar electrodes function as the anode of one cell and the cathode of another cell.

In arc welding, an electrode is used to conduct current through the work pieces to fuse the two pieces together. Depending on the process, the electrode is either consumable, such as in the case of gas metal arc welding or shielded metal arc welding, or non-consumable, as in gas tungsten arc welding. For a direct current system the weld rod or stick may be a cathode for a filling type weld or an anode for other welding processes. For an alternating current arc welder, the welding electrode is not considered to be an anode or cathode.

As you may have guessed, electrodes are also used extensively in the sciences, with materials analysis and the life sciences both making use of these versatile electrochemistry tools. Since they are invariably part of instruments which measure electrical charges of materials, analytes and other samples, they are used in a wide variety of different instruments across an even wider range of applications in the laboratory and in portable instruments which can be taken into the field or onto a production floor for quality control purposes. Electrodes are also an essential component of any instrument used for conductivity testing, impedance testing and similar applications.

Electric currents are sometimes run through nonmetallic objects to alter them in numerous ways and to measure conductivity for various purposes. Some examples include EEG, ECG, ECT and defibrillators in the field of medicine, brainwave detection, electrophysiology applications in biomedical research facilities, electrochemical analysis and electrolysis, to name only a few of their many different uses.

Electrodes are also used in electrochemiluminescence, which is a useful technique for analytical purposes where the easier reaction control offered by the ability to apply electrode potential is desirable. This makes the technique an improvement over chemiluminescence without the use of an electrode, at least for certain applications where higher sensitivity is an asset to the analytical process.

The list of applications above barely scratches the surface. The use of electrical energy in our homes, consumer goods, medical devices, scientific instruments and an enormous number of other products which are an indispensible part of modern life would be unthinkable in their absence. Electrodes are something with far too many uses to list; even if your career doesn't involve any sort of work in the laboratory, you have plenty of reasons to be thankful for their existence.


Monday, September 19, 2011

How to Weld - Choosing the Correct Process


Learning how to weld can be as easy or as complex as you make it. Virtually each welding job will have different requirements involving the material to be welded, the type of filler metal for the weld and the welding process itself. Some processes such as Mig or Tig welds can be used on different materials as long as the welding equipment is set up to accommodate that particular material.

General Welding Processes

There are three common welding processes that are used in welding workshops, manufacturing businesses and for home workshop and farm use.

Mig Welding

Mig stands for Metal Inert Gas or The Gas Metal Arc Welding process (GMAW). this process in most likely the most common process today. Its basically an arc welding process that utilizes a continuous wire feed of an electrode that is shielded using an external gas source. the components to make up the welding system comprises of the wire feed unit, a cable and weld gun plus the welding power source. Shielding gas is fed through the welder cable along with the electrode.

Being the most versatile this is the easiest way to learn how to weld sheet metal through to heavy work and how to fillet weld heavy plate. The versatility of a Mig means they can be used in all positions, can weld different materials such as mild steel, stainless steel or aluminum, and in most thicknesses. A properly set up machine will produce high quality welds that require minimal clean up.

The Tig Welding Process

Stands for Gas Tungsten Arc Welding (GTAW) or more commonly Tungsten Inert Gas process (TIG)

Learning how to Tig weld is more difficult than the mig process as the operator must control the welding torch and the filler material simultaneously. The process involves an arc being struck to the work using a tungsten electrode in the hand-piece, filler material is then applied through the resulting arc. In some instances such as sheet metals no filler rods are used as the join is simply fused together using the arc. Obviously this requires a neat joint without gaps.

Tig welds preformed properly will give an outstanding quality finish with high strength. They require minimal clean up as there is no slag or soot to deal with. Most effective for welding stainless steel and aluminum sheet metals, pipe work and products needing a neat tidy finish.

Arc Welding.

Next to gas the Arc welding process is the oldest of welding processes. Still used extensively in industry and for home use learning how to arc weld is a somewhat easier process. However having said that the application of the process can be complicated in the choice of welding electrodes. Arc weld electrodes have a flux coating that generates a shielding gas to protect the metal from atmospheric contaminants, they increase deposition rates and covers the weld with a slag coating. There are many specialist electrodes available such as for hard facing and pipeline welds that are required to have x rays for quality.

Arc welding can be used for welding mild steel, hardened steels, stainless steel, cast iron and numerous specialty steels. Slag deposits require removal so some clean up is needed. Various electrodes require more or less clean up.

As arc welders do not require an external gas resource they are ideal for outdoor and site work, and are widely used in maintenance and construction work.


An Overview of Welding Machines - Gas and Arc Processes


This article sets out to outline the different types of welders used in the metal fabrication industry and their respective applications. Welders can be broken down into two categories: those that use a flame for their heat source and those that use an electric arc.

Flame welders consist of four major parts: compressed gas cylinders, regulators, hoses, and a handle. The gas cylinders contain a fuel and an oxidizer. Acetylene and oxygen are the most common fuel-oxidizer combination, but many people use propane for fuel because of Acetylene's relative instability. Each cylinder has a manual valve that when open allows gas to flow into the regulator. Each gas cylinder has an adjustable regulator that reduces the pressure of the gas from the higher cylinder pressure to a consistent pressure. Adjusting the regulators allows adjustment of the flame. The regulators are connected to the welding handle by rubber hoses. The handle contains on/off valves for both the acetylene and oxygen, and a threaded adapter to allow attachment of various welding, brazing, and cutting tips. Because of this design the gas welding outfit is the most versatile - with the right accessories nearly any operation can be completed. A skilled operator can also weld thin metal with precise control of the welding flame. Gas welding can easily result in a contaminated weld if the operator is not diligent and the flame is not properly adjusted.

Arc welding is broken down into three categories of machines, based on the electrode material and the shielding gas type. SMAW is the simplest process, which stands for shielded metal arc welding. An electrode holder clamps a long metal electrode coated in a flux mixture. An arc is struck between the electrode and the work piece. The electrode metal is deposited to fill the weld, and the flux burns and creates a shielding gas. GTAW welding, or more commonly referred to as TIG welding, stands for Gas Tungsten Arc Welding. GTAW welding employs an inert gas, usually a mix of argon and co2 to prevent the weld from being contaminated by oxidation. The Tungsten in GTAW stands for the tungsten electrode that is used to support the welding arc. The work piece forms the negative side of the circuit, and a tungsten electrode forms the positive side, which is contained in a handle, referred to as the 'torch'. The welding operator manipulates the arc using a voltage control foot pedal and by varying the distance of the torch from the work. The weld is filled in using welding rod. This technique is similar to gas welding. GTAW welding is slow, but it allows for a high degree of precision and the welding of exotic metals such as titanium. GMAW welding stands for gas metal arc welding, also known as MIG welding. Instead of a tungsten electrode and a separate filler rod the two are combined. A metal electrode is constantly fed out which both supports the electric arc and adds filler metal to the weld. Inert gas shields the weld and prevents contamination, as in GTAW welding. GMAW welding is fast as well as versatile. FCAW stands for flux cored arc welding. FCAW employs the same electrode feeding mechanism as GMAW welding, but instead of inert gas for shielding the welding wire contains flux, which when burned creates a shielding gas cloud around the weld.


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Flux Cored Arc Welding - Dual Shield Vs Self Shielding Electrodes


When it comes to flux cored arc welding there are two choices for electrode types. No matter what you are welding sooner or later you will need to understand the differences between these types of electrodes and what they do. The two types of electrodes are:


Self Shielding
Dual Shielding

Self shielding is an electrode that does exactly what the name states. It is a self shielding electrode that does not require any other form of shielding from the air around it. Flux cored arc welding self shielding electrodes are just like stick welding rods turned inside out. The electrode is a hollow tube that contains a flux inside of the center. This flux inside turns into gas when the welder starts a arc and heats it up to the needed temperature. The best way to describe this process is by comparing it to a road flare burning. Once the power inside of the flare is ignited it starts producing a steady flow of gas. This is the gas that protects the weld area from the gasses in the air that contaminate welds. Self shielding electrodes are a great choice for welding in windy conditions or for hobbyists that have a MIG welding machine and don't want to bother with maintaining a bottle of shielding gas.

Dual shielding electrodes are just like the self shielding electrodes with one main exception. They also require the use of a shielding gas while welding. The main advantage of dual shielding electrodes is that the weld is cleaner then a self shielding wire and the flux inside also have additional filler metal added to it. The dual shielding electrode provides the fastest deposit rate of all of the manual welding processes. It can produce as much as 25 pounds of weld in a single hour. The down side is that welding in conditions that have high winds may cause weld porosity from a lack of shielding gas. When it comes to dual shielding electrodes they typically require a C25 gas. This is a bottle of compressed gas that contains 25% Co2 and 75% Argon mixture. This shielding gas must be used in addition to the flux inside of the wire. This also means there is additional cost for the gas and it requires setting the gas flow rate to appropriate flow rate for the conditions the welder will work in.

Finally it just comes down to weighing the cost.vs your welding condition that will determine the type of electrode you will need.


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A Guide to Gap Electrodes


Are you looking to learn a bit about gap electrodes? Perhaps you're new to micro gap welding and wanting to know if you can benefit from purchasing one. Or maybe you're just curious as to their applications. Whatever the case, here's a quick guide to help you understand gap electrodes.

Gap electrodes-what they are and how they're made

Gap electrodes are tips you use in welding. Also called "parallel GE," these tips comprise two separate halves. Within the electrode holder, each half is usually held carefully in place in left and right positions. The halves of the electrode may be:

• Bonded - In many cases, your electrode holder may require an electrode that is bonded together. In this situation, the electrode gap is predetermined, meaning you have no room to customize the gap. The two halves are bound together by an adhesive layer that serves as an insulator.

• Free standing - In other cases, you may purchase a welder that has a specially designed electrode holder. In this case you are able to customize the distance between each half of the electrode, allowing for more versatility. It works by utilizing free floating gap electrodes.

Which is better? Well it depends on your specific needs. Talk to a professional supplier to discuss what's right for your applications.

How different GE welding techniques work

Gap electrodes are especially advantageous in situations where you're welding a piece that has insulation on one side. In this situation, the welding current will:

1. Travel down one half of the electrode

2. Go through the materials being welded

3. Rise up the other half of the electrode

This is known as a series configuration.

Step welds are a bit different. Each half of the electrode touches a different material, allowing the weld current to pass over the material interface.

When you use parallel gap electrodes, each half targets the piece from matching directions. Regardless of which form of welding you're attempting, there's a GE to fit your individual need.

Choosing a supplier

If you're in need of gap electrodes, it's crucial that you choose the right supplier. That said, you need to know what to look for in a welding supplies provider. Make sure the company:

• Has been around for awhile. You don't want to deal with a fly-by-night organization.

• Is knowledgeable. You need someone who can answer all of your product and application related questions.

• Is reasonable with prices. There are a lot of people out there who will try to rob you blind. Don't fall for it. Only go with a company who has competitive prices for GE.

• Offers other services. If you're in the market for GE, chances are you'll need other services along the way. Choose a company that also offers things such as CNC Milling Services, CNC Machine Shops and CNC Lathe Turning. That way, one company can handle all of your needs.

If you're in need of gap electrodes or other welding products, begin searching for a reliable, knowledgeable supplier today.


Sunday, September 18, 2011

Material Specifications: Welding Rods Electrodes and Filler Metals/Part C/Fx002C

This study covers the world outlook for coiled and spooled continuous cored metal wire electrodes for automatic arc and inert gas welding excluding hard-facing electrodes across more than 200 countries. For each year reported, estimates are given for the latent demand, or potential industry earnings (P.I.E.), for the country in question (in millions of U.S. dollars), the percent share the country is of the region and of the globe. These comparative benchmarks allow the reader to quickly gauge a country vis-à-vis others. Using econometric models which project fundamental economic dynamics within each country and across countries, latent demand estimates are created. This report does not discuss the specific players in the market serving the latent demand, nor specific details at the product level. The study also does not consider short-term cyclicalities that might affect realized sales. The study, therefore, is strategic in nature, taking an aggregate and long-run view, irrespective of the players or products involved.

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