Welding Machines

In industrial context, welding refers to a fabrication process that joins materials such as metals and thermoplastics, by causing coalescence. This is typically done by softening the work pieces and adding a filler material, which is often a welding rod, to form a pool of molten material that cools to become a strong joint. Various processes and energy sources are used for welding, such as gas flame, electric arc, laser, electric beam, friction, and ultra sound.

Welding machines can be broadly classified into different categories depending on the type of welding processes and equipment used during the process. Some welding machines use transformers for converting high voltage, low current electricity into high current low voltage, often between 17 to 45 volts and 190 to 590 amperes. These types of welding machines are the least expensive and allow welders to select the output current by either moving the core of the transformer in and out of the magnetic field or by allowing the welder to select from a set of taps on the transformer.

Some welding machines use an internal combustion engine or an electric motor to drive the alternator or generator present in these machines. The process used is similar to transformer based welding machines as power is first converted into mechanical and back to electrical energy to achieve the step-down affect.

Inverter based welding machines use high-power semiconductors such as the IGBT for building a switching power supply capable of handling high loads of arc welding. These machines convert utility electricity into high voltage and store it in a capacitor bank. The stored energy is then transferred to a secondary transformer for producing the desired welding current.

Welding machines have simplified different types of machining jobs undertaken in small and large manufacturing companies. Automated welding machines are also in use and have helped in increasing the effectiveness of welding processes.

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How to TIG Weld Aluminum and Get the Stack of Dimes Look, Even With an Old TIG Welding Machine

Wanna learn how to TIG weld aluminum?

First you need a decent TIG welding machine. Not a great one, just a decent one. Already got one? You might have an old Synrowave 300 or a DialArc, an old Hobart CyberTIG or you might have a brand new Miller Dynasty 350.

Know what? It doesn't really matter. The same principles apply. If you have an old as dirt TIG welding machine, you can still make good aluminum TIG welds. Weld beads that look like a stack of dimes.

First lets look at machine settings:

Set the polarity to A/c (alternating currrent)
Make sure to set the high frequency to continuous
Set the amperage to about one and one half amps per one thousandths of inch of thickness. (up to about 250 amps then things change quite a bit)
Set both the contactor and amperage switches to the remote positon.
Set the argon or argon/helium torch shielding gas to around 15 cfh. (if you are using a #7 cup) less if the cup is smaller.
Notice I said argon or argon/helium? Argon is not the only game in town. In fact, if you TIG weld any aluminum over about .063" thick, adding helium to the mix makes a huge difference.
Now lets talk tungsten electrodes
2% thoriated have received a lot of bad press for the radioactivity issue but they do work.
2% lanthanated electrodes are a really good all purpose electrode...good for TIG welding aluminum as well as steel.
Use the smallest electrode that will get the job done without quivering at max amperage.
Remote amperage control...you need a foot pedal. Period.
Once all the settings are ok, and assuming you are welding on 1/8" thick aluminum, grab a piece of 4043 filler rod in 3/32 diameter (rarely will you use a rod as thick or thicker than the metal you are welding)
extend the electrode tip about 1/4" past the tip of the TIG torch cup and pre purge the gas by tapping the foot pedal.
hold the torch like a big first grade pencil. touch the tip of the tungsten to the metal and then pull it back about 1/8 inch. flip your helmet down and press the pedal to initiate the arc.
don't melt the aluminum right away though, watch the black stuff cook away from the arcs cleaning action before you melt the metal. Then press the pedal far enough to create a puddle that is about 3-4 times the thickness of the metal you are welding.
Now comes the part on how to achieve the "stack of dimes" look. You get that by adding the same amount of rod and by moving the torch the same distance each time you add rod. Add rod, Step ahead 1/8 inch,Add rod, Step ahead 1/8 inch,Add rod, Step ahead 1/8 inch, lather rinse repeat. If you do this consistently, you will get evenly spaced ripples that look like a stack of dimes.

Of course it looks different from underneath the welding helmet and it is harder than it sounds, but this is really how you do it. All that is left is the doing. It takes practice and lots of quality seat time.

To see a Video on TIG Welding Aluminum and how to get the "stack of dimes" look, as well as a whole bunch of TIG, MIG, STICK welding tips and a pantload of other welding information, visit http://www.weldingtipsandtricks.com/.

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Working With a Welding Machine Made Easy

The industrial needs are increasing each day and almost all sector of activity make use of the welding technique in one or the other way. The welding processes have become so important that the companies are hiring welders who have thorough knowledge of the operation process, capacity to read welding symbols from blueprints and advanced working skills. These are basic characteristics that the companies seek in the welders. But the most important thing is the way the welder handles the machine and how he operates it. Certain protective steps should be essentially taken for making sure that the welding process is done safely and efficiently. The following steps would help the welding process easier.

The first and foremost thing to consider is the place where the prospective welding machine would be placed. It is advised to keep the machine in a dry area where air circulation is proper and there is proper ventilation. The air circulation is absolutely important because during welding all sorts of chemical fumes would be emitted following the technological process. Such fumes are hazardous and are highly risky for the operator's health. If at all open air access is not possible, the machine should necessarily have special ventilation which would be placed very close to the machine. Thus the air circulation can be assured to an extent. Moreover it is also important to make sure that there are no flammable substances anywhere near the welding machine. Substances like paints, solvents or any other chemicals of flammable nature increases the chances of accident exposures.

The second important thing would be the cleanliness of the area where welding takes place. The area should be cleaned prior to the welding process since any trace of paint, oil, rust or other impurities can possible reduce the efficient functioning of the welding machine. Here the need for protective apparels arises which is very important. The welder operating the machine should essentially wear protective gadgets like protective gloves which are fireproof, apron and a special helmet along with protective glasses. Such apparels would help the welder to prevent exposure to radiation, sparks, spatters or fumes that occurs during the usage of the welding. Above all, yet another important to be noted is that all the settings of the welding machines should be arranged in accordance with the characteristics of the metal that is going to be welded. If that is not done, then burn outs or low arc penetration would happen.

The welding machines are usually purchased for industrial use but if you are an amateur welder or a novice, you don't need to buy the machines. Evaluate the work before setting out to buy the welding machines and welding equipments. Compare the extent of investment possible along with the desired results. If you are only doing occasional welding, then a rented welding machine is more than enough. But if the welding machine constitute almost 60% of the activity, then it is better to buy one. There are many other cost effective options like purchasing used welders which are reliable due to the liability of the engine.

Gavin Bone is an author for Welders. He has written articles arc welder. For information visit our site Plasma Cutters

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