Here are a few tips about MIG welders and how to make the best purchase picks. Welding faster may sound appealing, but aside from practice, there are few shortcuts when creating a strong weld. In fact, unless a situation calls for a fast-moving weld, there’s a good chance that slow and steady is the way to go. An online search for ways to weld faster, will yield either descriptions of the ways automated welding has increased welding speed or press releases from companies who claim their gas or electrode holds the key to improving welding speed. In other words, it can seem like spending a lot of money is the only way to weld faster. However, for those looking for some ways to save time on their welding projects, there are some ways to weld faster for certain projects. While it’s not always a good idea to find a way to weld faster, there are situations when welding faster may produce a better product or a few simple changes can speed up the time on task.
MIG welders use a wire welding electrode on a spool that is fed automatically at a constant pre-selected speed. The arc, created by an electrical current between the base metal and the wire, melts the wire and joins it with the base, producing a high-strength weld with great appearance and little need for cleaning. MIG welding is clean, easy and can be used on thin or thicker plate metals. Similar to MIG welding, flux-cored arc welding (FCAW)* is a wire-feed process but differs in that self-shielded flux-cored welding does not require a shielding gas. Instead, flux-cored wire is used to shield the arc from contamination. This is a simple, efficient and effective welding approach, especially when welding outdoors, in windy conditions or on dirty materials. The process is widely used in construction because of its high welding speed and portability.
In many shops, the operator has to go to a tool room or supply area for a new contact tip, coil of wire or other welding accessory. This takes valuable time away from the welding cell and slows down overall productivity. To improve the operating efficiency and minimize wasted time, companies should stock at least a limited supply of all necessary items near the welding station – this includes shielding gas, flux and wire. Another helpful productivity enhancing tip is to switch to larger spools of wire such as from 25 lb. spools to 44 or 60 lb. spools to even larger packages of 1,000 lb. reels or 1,000 lb. drums. A simple switch like this means less changeover time, which adds up over the weeks, months and years. Shops should also be on the lookout for shielding gas waste. A simple device called a surge turbine can be placed at the end of the gun to provide a digital readout of the gas surge and flow rate. If the surge rate is high, investing in a surge guard can reduce the pressure, eliminating gas surges and waste. Leaks in the gas delivery system can also create a potential loss of money. By looking at the amount of consumables purchased each year and then examining the total gas purchased, a company can determine if there is a significant loss. Welding manufacturers and distributors should be able to provide average utilization figures so that loss can be detected. If there is a loss suspected, one of the easiest ways to check for leaks is to shut off the gas delivery system over the weekend. Check the level on Friday evening and then again on Monday morning to determine if gas was used while the system was in shut down mode. Looking for the best Welding Supplies? 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.
So pay attention to the way you grind your tungsten. You have probably read that Tungsten electrodes should only be ground longitudinally, not sideways or the world will come to an end and dogs and cats will start sleeping together. Take it from someone who has been TIG welding for over 30 years and has sharpened electrodes every way imaginable including using a cutting torch. That’s right I said cutting torch. It does matter how you grind tungsten electrodes. There is a big difference between a tungsten electrode ground sideways on a 36 grit stone to one ground properly on a fine diamond wheel. But there is not much difference between a tungsten ground sideways on a fine wheel and one that has been ground longitudinally on the same wheel… Unless you are welding razor blades or at extremely low amperages. or doing automatic low amperage orbital welding. A lot of people will argue this point with me. I dont care. I cant make myself say that tungsten grinders make a lot of difference when I dont really believe it.
MIG welders advices: how to become a better welder and how to pick the best welding equipment. How do I choose what size Tig Welding Rod should I use for the job? For sheet metal up to 1/8” thick, don’t use a welding rod that is bigger than the thickness of metal you are welding…at least not much bigger. A good example…is using a 3/32 rod for welding .040 metal. That will just give you a fit. The amperage is low and the weld puddle needs to be small in order to prevent blowing a hole…and then when you dip the rod into the puddle, the rod is a big heat sink and sucks the heat right out of the puddle making it hard to maintain a consistent size bead. But Beginners should probably not be practicing on really thin metal. If you are a beginner you should be practicing on around 1/8 ” thick metal, and the bigger the rod, the easier it is to feed. For 1/8 ” metal, Use larger diameter rods (3/32” to 1/8”) So here is the rule….thin metal, use a thin rod Thick metal, use a thicker rod. This might seem like a no brainer, but I have answered a lot of questions like this about the rod melting before it gets to the puddle. If torch angle and arc length are right, its usually the rod size.
For the best control of your weld bead, keep the wire directed at the leading edge of the weld pool. When welding out of position (vertical, horizontal or overhead welding), keep the weld pool small for best weld bead control, and use the smallest wire diameter size you can. A bead that is too tall and skinny indicates a lack of heat into the weld joint or too fast of travel speed. Conversely, if the bead is flat and wide, the weld parameters are too hot or you are welding too slowly. Ideally, the weld should have a slight crown that just touches the metal around it. Keep in mind that a push technique preheats the metal, which means this is best used with thinner metals like aluminum. On the other hand, if you pull solid wire, it flattens the weld out and puts a lot of heat into the metal. Finally, always store and handle your filler metals properly. Keep product in a dry, clean place — moisture can damage wire and lead to costly weld defects, such as hydrogen-induced cracking. Also, always use gloves when handling wires to prevent moisture or dirt from your hands settling on the surface. When not in use, protect spools of wire by covering them on the wire feeder, or better yet, remove the spool and place it in a clean plastic bag, closing it securely.
First, practice handling the gun without actually welding. Rest its barrel in one hand, and support that hand on the table. The other hand operates the gun’s trigger. Stand in a comfortable position and move the gun steadily over the work surface. Adjust your posture and gun movement so that they feel natural. Attach the work lead to the workpiece, and hold the gun so the wire meets the weld surface at about a 30-degree angle. Touch the wire very lightly to the surface, squeeze the trigger, and gently pull the gun toward you to make your first test weld. The wire should melt off into the weld puddle at an even rate and make a steady crackling noise as you go. Adjust the welder settings if needed. Source: https://www.weldingsuppliesdirect.co.uk/.