Here are a few tricks on MIG welders and how to make the best purchase choices. Flat-Position Welding Increases Welding Speed : It’s common knowledge that welding in a horizontal position will be the easiest and fastest way to weld. A flat position is not as taxing to maintain and the welding puddle will stay in place. Take some time to evaluate each project before beginning in order to make sure the majority of welds can be completed in this position. If a job calls for vertical welding, see this article about vertical welding. Core Wire Feeder Increases TIG Welding Speed: For professional welders hoping to speed up TIG welding, a core wire feeder will add filler metal through an automated process. Watch this video on how it works. This enables welders to work with both hands and to maintain a constant flow of wire into the welding puddle. Ed Craig at the Frabricator writes about the wire feeder process first developed in Europe, saying it is “suitable for all-position welding on materials of any thickness, the process addresses traditional GTAW limitations and can enhance both manual and automated TIG weld quality and productivity.”
TIG welding is similar to to a MIG welder as it uses an electric arc in the same was as MIG welding does but differs in a few ways. Instead of a continuous spool of consumable wire, a TIG welder uses long tungsten welding rods that are manually slowly fed into the weld puddle to join the metal. TIG welding requires gas, usually argon, to protect and cool the weld puddle from external contamination. TIG welding is more suited to welding thinner materials such as stainless steel and aluminium as you can get the power down lower to reduce the risk of blow through and can even weld two dissimilar metals. Suitable for tricky welds such as S curves but TIG welders are still capable of welding heavier materials depending on the machine. TIG welding takes more practice that MIG welding as the process is much more manual with controlling the torch, welding rod and gas by hand (and foot for the gas) but once mastered will produce the highest quality welds making it the better choice where perfect, precise welds are required but due to the manual process is the least productive.
Delivery of parts to the welding station in an organized and logical fashion is also a way to reduce welding costs. For example, one company was manufacturing concrete mixing drums. In the fabrication process, the company produced 10 parts for one section, then went on to make 10 parts of another drum section, etc. As pieces came off the line, they were put onto the floor of the shop. When it was time to weld, the operator had to hunt for the pieces needed and sort through them. When the outside welding expert pointed out the amount of time being wasted in this process, the company started to batch each one on a cart. In this way, the pieces needed to weld one drum were stored together and could easily be moved to the welding area. This type of scenario is also true for companies that may outsource parts to a vendor. Though it may cost more to have parts delivered in batches, it may save more in time than having to organize and search through parts to be able to get to the welding stage. How many times each piece is handled in the shop may be an eye-opener to reducing wasted time. To measure such an intangible as this, operators are asked to put a soapstone mark on the piece each time it is touched – some companies are surprised to find out how many times a part is picked up, transported and laid down in the manufacturing process. In the case of one company, moving the welding shop closer to the heat treatment station eliminated four extra times that the part was handled. Basically, handling a part as few times as possible and creating a more efficient production line or work cell will reduce overall costs. Searching for the best Welding Fume Extraction? We recommend Welding Supplies Direct & associated company TWS Direct Ltd is an online distributor of a wide variety of welding supplies, welding equipment and welding machine. We supply plasma cutters, MIG, TIG, ARC welding machines and support consumables to the UK, Europe and North America.
Put a glove, block of wood, folded up heat resistant cloth or something non-conductive on the welding table to rest your arms or elbows on and to protect your arms from shock hazard: Do you enjoy getting shocked? Me neither . tig welding aluminum with your high frequency switched to continuous means that the high freq is always looking for a path to follow. So even resting your forearm on the metal table can let that high frequency current bite you just when you least want it, like right when you are near and edge and you are being extra careful not to melt the edge away and then ZAP!. Who needs that? Put a glove, block of wood, folded up heat resistant cloth or something non-conductive on the welding table to rest your arms or elbows on and to protect your arms from shock hazard. Also do whatever it takes to rest your torch hand on a steady object. Again, a block of wood, a balled up tape ball etc can all be used to give you something to rest your torch hand on.
Several MIG welders tips: how to become a more skilled welder and how to pick the best welding equipment. Use the smallest tungsten that will get the job done. Use the smallest tungsten to get the job done. …within reason. Another way of saying this is don’t just use a 1/8” electrode for everything. There are jobs where a 1/8” electrode is great like for welding 3/16” thick aluminum. But what if you are welding on the edge of a .030” turbine blade? A .040” electrode will be plenty to handle the 15 amps and will give much better starts than even a 1/16” electrode. Too large an electrode can cause an erratic arc and contamination…and A bad start where the high frequency tries to arc up inside the cup and off the side of the tungsten can easily melt off a thin edge and scrap an expensive part. 2% thoriated or lanthanated tungsten electrodes hold up at high amperage better than most all other electrodes. When welding at higher amperages, often times you can use one size smaller electrode by using 2% thoriated or lanthanated. And that is a good thing.
Improper drive roll selection and tension setting can lead to poor wire feeding. Consider the size and type of wire being used and match it to the correct drive roll. Since flux-cored wire is softer, due to the flux inside and the tubular design, it requires a knurled drive roll that has teeth to grab the wire and to help push it through. However, knurled drive rolls should not be used with solid wire because the teeth will cause shavings to break off the wire, leading to clogs in the liner that create resistance as the wire feeds. In this case, use V-grove or U-groove drive rolls instead. Set the proper drive roll tension by releasing the drive rolls. Then increase the tension while feeding the wire into your gloved hand until the tension is one half-turn past wire slippage. Always keep the gun as straight as possible to avoid kinking in the cable that could lead to poor wire feeding.
The arc is shaped like a cone, with the tip at the electrode and the base on the metal being welded. The closer the electrode is held to the metal, the smaller the base of the cone — but as you pull the electrode farther away, the base (and puddle) gets larger. If the puddle gets too large, gravity will simply pull it away from the base metal, leaving a hole. This is why thin-gauge metals are especially challenging for beginners. Perhaps the most important skill needed for TIG welding is moving the torch in a controlled manner, with steady forward movement, while keeping the gap between the tip of the electrode and the base metal consistently small — usually in the range of 1/8 inch to 3/16 inch. It requires a lot of practice to precisely control the arc length, keeping it as short as you can without allowing the electrode to touch the base metal or filler rod. Source: https://www.weldingsuppliesdirect.co.uk/.