Installing your mig welding wire is really quite simple. The first step is to make sure that you are using a very high quality mig welding wire. Why? You can have so many troubles with mig welding wire not feeding, burning back, excess spatter, birds nesting and so on.

Assuming there is no old spool of mig wire on the mig welder. The first think you have to do is physically open the welding machine or wire feed case up.p>

Then you will have to remove a cotter pin or a large plastic nut that is attached to the hub or axle the welding wire will slide onto. Now open up the box of mig wire, check that it is the correct size wire that you want to use and the correct type of wire. Also give it a quick glance and check for rust.

Lift up the spool and slide it onto the axle/hub. Replace the cotter pin or plastic nut.

Now go to the end of the mig welding gun and remove the nozzle / shroud. This will either pull off or screw off depending on the brand of welding torch. When it’s off, remove the contact tip by unscrewing it with pliers.

Set the nozzle and contact tip aside.

Go back to the mig wire, and in between the spool of mig wire and where the welding torch attaches to the front of the machine or remote wire feeder you will find the feed rollers or drive rollers.

There will be some kind of latch which can be flicked open. This action will raise the top feed roller and allow you to feed the wire onto the drive rolls.

Note that on the feed rollers there are usually two grooves. The wire needs to sit in one of these grooves. On the side of the feed rollers will be a punched marking showing what size wire to use in which groove.

Usually mig welding machines come with two different sized grooves. For example 0.9mm and 1.2mm which is 0.035” and 0.045”.

Make sure that the mig welding wire diameter fits the right sized grove in the feed roller. When running a precision welding wire you need to use the right feed roller groove for the correct diameter sized mig wire.

You can get away with using slightly different sized feed rollers when you run a cheapie low quality mig wire. Why is this? This is because the wire diameter tolerance will go up and down. So the wire will be getting thicker and thinner all the time which will compensate for the slightly wrong sized feed rollers.

I do not at all recommend this for anyone who is serious about making money in a production welding environment or welding and fabrication business. It will cause to much trouble.

Now you will have to carefully and I stress carefully find the end of the mig wire and hold onto it and don’t let go. If you do it will go whirl, whirl, whirl and you will have a big mess of mig wire all over the place.

With the end of the mig wire feed it into the driver rollers, you will have to go through a small feed tube. This helps guide the wire over the feed rollers.

Keep feeding the wire through past the driver rolls and into the start of the mig welding gun. Feed it through about a foot or so.

Lower and lock down the latch for the drive rollers, and adjust it right back to number one or the lightest setting possible. Then screw / adjust the tension down a bit.

Next if you are using gas, turn off the bottle to save your expensive welding gas lay you welding gun and cable out straight from the welder and pull the trigger. The wire will slowly fed through the liner and pop out at the tip holder. You can crank up the feed speed adjuster to get the wire through faster.

Now when the wire emerges put the contact tip or contact tube back on. Put the nozzle back on and trim the wire to about half an inch sticking out.

You are just about done now. Turn you gas back on. Now ideally you want the wire feed tension mechanism to be as light as possible so that it does not deform the shape of the welding wire. Deforming the shape of the welding wire will case premature wear on the feed rollers simply because of too much force. It will cause irregular wear on the contact tip and the welding wire will have tiny bits of material shaved and squeezed off it which will go down into the liner of the torch, and over time cause it to build up internal resistance which will cause more trouble welding down the track.

For more go here

http://www.learn-how-to-weld.com/mig-wire-installation.html

Cheers,

Peter Apalais

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The plasma cutting process has been around for more than 50 years starting during the World War II era. The war demanded a faster and more reliable way to improve aircraft development, thus the plasma cutter was born allowing a protective barrier of inert gas around an electric arc to protect the weld from oxidation.

Over the course of the next several years, the plasma cutting process has drastically developed with further testing and improvements. At this time, it was discovered that by restricting the opening through which the inert gas passed, the heat produced by the process was tremendously elevated. At the same time, the smaller opening caused the flow of gas to speed up dramatically, ultimately blowing out a channel in the work.

In the mid sixties, plasma arc cutters began seeing commercial use with everyday applications as the process became a bit more common even though it was still extremely expensive to carry out. Large factories were able to afford the advanced technology and thrived on the ability to cut metal quickly and more efficiently.

Over the years, plasma cutting has worked its way into manufacturing plants, shops, and even homes. As the manufacturing of the plasma cutter cost has been reduced by development of technology and the competition of many affordable units such as Longevity plasma cutters, the plasma cutter process is now widely available and affordable in comparison to the early days and has become a must have tool for the working individual seeking or needing to cut metal.

Currently, plasma cutters are dual voltage and there are units ranging from 20 to 400amps out on the market. With plasma cutting being such a powerful and efficient tool to cut metal, we are sure that a plasma cutter will not be replaced anytime soon and the technology advancement will only fine tune this already convenient technology.

If you don’t own a plasma cutter, now is the time to give it a shot. There are plenty of suppliers out there and do you research, but we currently recommend Longevity plasma cutters for the price and warranty period. Give them a try.

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Tack welding is used throughout the welding and fabrication industry. Even the most basic welding jobs at home will require you to do “tack welds”.

Fabrication and welding techniques call for the need of tack welding. Manufactured weldments and components require tack welding to hold assemblies and parts together during initial fit up and measuring.

Tack welding is used in mig welding, tig welding and arc welding. p>

A tack weld is a small weld that is placed in critical positions of a project or work piece to hold it in place, keep it square and stop it from warping out of square.

An example of a tack weld would be if you were making a gate out some steel box section. The first step would be to cut the steel to the required lengths. Then you would lay the four lengths of steel on your workbench or onto the floor. You would then use a square to align the steel into a rectangle and clamp them together.

The tack welds are placed on all four corners so that it is held true and square.

These small tack welds will when you full weld the steel together, prevent the steel frame from twisting and bend out of square a lot more than if you just started fully welding it all up.

Also tack welds are small so that if you make a mistake when you cut and square things up, it is easier to grind away a small tack weld as opposed to a large full weld.

http://www.learn-how-to-weld.com/mig-welding-basics-2.html

Cheers,

Peter Apalais

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Plasma cutters can cut steel and other metals of different thicknesses using a plasma torch. Plasma can also be used for plasma arc welding and other applications.

Plasma cutters are available in various shapes and sizes. All plasma cutters function on the same principle and are constructed around roughly the same design. Plasma cutters send pressurized gas, such as nitrogen, argon, or oxygen through a small channel. In the center of this channel, you’ll find a negatively charged electrode.

Plasma cutters can cut different shapes in metals properly. It is a very simple and economic technique. With the help of these cutters, the cutting work can be done accurately, in full speed and cut any type of metal in any shape. Due to low level skill, plasma cutters are threat to conventional metalworking tools. Plasma causes the energy to break apart the gas molecules and the atoms begin to split. Generally atoms have protons and neutrons in the nucleus, surrounded with electrons. But in case of plasma cutters, electrons separate from the nucleus. Once the energy of heat releases the electrons from the atom, the electrons begin to move around quickly. If you notice most of the electrons are negatively charged and leave behind positively charged nuclei, known as ions. Electrons crash with other electrons and ions, which releases vast amount of energy, creating plasma and unbelievable cutting power.

Plasma cutters are widely used in auto shops as well as by car manufacturers to customize and create chassis and frames. Even construction companies use plasma cutters in large-scale projects to cut and fabricate huge beams or metal-sheet goods. Locksmiths use plasma cutters to bore into safes and vaults when customers have been locked out.

One major benefit of plasma cutter is that the surface of the metal outside of the cutting area remains relatively cool; this prevents the warping and paint damage that can occur with other flame cutters. A thin heat affected zone also allows the use of templates for precise curved line cutting. Plasma cutters do well as gougers and can pierce metal quickly and accurately.

Plasma cutters are also used in CNC (computer numerically controlled) machinery. The idea behind CNC tables is to allow a computer to control the torch head making clean sharp cuts. Nowadays, CNC plasma equipment can cut thick material, which provides opportunity for complex welding seams on CNC welding equipment that is not possible otherwise. For cutting thinner material, plasma cutter is replaced by laser cutting, due to superior hole-cutting abilities. CNC plasma cutters are also used in HVAC industry. In the present scenario, there is more development in CNC plasma cutting Machinery. In the past, cutting machine was horizontal in shape, but due to improvement in technology, vertical CNC plasma cutting machines are available.

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Brayan Peter is an expert author for Welding Supply, Welding Equipments. He written many articles like Welders, Welding Machines, TIG Welding Equipment, welding helmets, Diesel Generators, Plasma Cutters. For more information visit our site http://www.everlastgenerators.com. Contact him at weldings.info@gmail.com

Storage and Handling

• After finishing gas welding, Always keep gas and oxygen cylinders with minimum of 20 feet distance between them. Or, divide them with a right firewall.
• As the cylinders can caught fire easily, keep the flammable and combustible materials away from cylinders.
• Store cylinders away from physical injure, heat, and tampering.
• Always maintain cylinders in an upright position. If possible, Chain them steadily to keep them from falling over.
• Ensure that the cylinder valves has been closed or not before moving.
• Defending caps or regulators should be kept in place.
• Roll cylinders on bottom edges to move it from one place to another place. Do not pull it.
• Try to reduce cylinder movement as much as possible, while transporting it.

General Gas Welding Safety Tips

• To lift up gas cylinders, use the equipments that are designed for lifting it. Do not use any other tools for lifting it.
• Check torches and clean only with the suitable tools.
• Blow-back protection torches must be used while welding.
• Always keep an eye on the equipments and ensure any leakages at all connections. This can be done by using an approved leak-test solution.
• Inspect hoses for leaks and worn places.
• Replace bad hoses at regular intervals.
• Keep fire extinguishers easily reachable places, at the welding site.
• Keep away hoses and cylinders from sparks, flames, and hot metal as the sparks create holes on it.
• To fire the flame in welder, always use a flint lighter.
• Stand to the side when opening cylinder valves.
• Use two-stage regulators whenever feasible.
• When using a single-stage regulator, open cylinder valves very slowly. This keeps rapid high pressures from exploding the regulators.
• When using a single-stage regulator, only open the acetylene cylinder valve 1/4 to 3/4 turn.
• Leave the wrench in place. By doing so, you can close the cylinder quickly in case of any emergency.
• Open and light acetylene first. Then open and adjust oxygen to a neutral flame.
• When shutting off the torch, first you have to close the acetylene torch valve You might hear a pop as the oxygen blows out the flame, but the flame will not burn up the acetylene line.
• When you done:
  • Close cylinder valves.
  • Bleed the lines to take pressure off regulators.
  • Carefully coil hoses.
  • Restore equipment.

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Learning how to weld is not as hard as you might think.

All you have to do is simply follow a few basic steps, to get that welding down pat. It’s like baking a cake or building a house. You need to follow a set way of doing things.

There are a few basic and easy to learn steps that you need to take into consideration before you even attempt how to stick weld or arc weld.

A lot of the time, people simply just rush in “guns blazing” and when they have a go at it half a dozen times and they can’t do it, they give up. Listen, like I’ve said, stick welding might seem a bit daunting at first. But once you learn these basic steps on how to arc / stick weld the whole process will become a lot clearer to you.

How do I know? I’ve been there and done that. I know how hard it can be to learn how to stick weld for a person who has never welded before in their life. Often the first timer will make a few silly mistakes that can spoil their first time stick or arc welding experience.

Things like:

• How to strike an arc and keep it going. This is a big issue for anyone who is learning how to stick weld. How do I do it? Why does it keep sticking to the job?

• What size welding electrode should I use?

• What type of welding electrode should I use?

• What about welding safety. What should I be aware of when welding? What will hurt me and put me at risk of injury? If you are new to welding, you might not be aware of what to look out for.

• Which way do I move the electrode?

• What power setting should I set my machine at?

All these and many more questions are what the DIY’er or learner welder need to find out.
You need to.

1.  Learn how to stick weld and arc weld the right way the first time.

2. By following a set of easy to understand step by step instructions.

Which means…

3. By having a successful first time arc welding experience, you will never have a negative experience, therefore your ability to learn will not be ruined by a bad first time experience.

To find out how you can learn how to weld, quickly fast and easy.
 
Head on over to learn-how-to-weld.com – this is a brand new site that is being developed to help people like yourself learn how to weld.

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Plastic welding and spot welding – both are almost similar to each other. There is a difference noted. In plastic welding, heat is supplied through convection of the pincher tips, instead of conduction. The two plastic pieces are brought together. At the time of welding, a jet of hot air is liberated. This melts the parts to be joined along with the plastic filler rod. As the rod starts melting, it is forced into the joint and causes the fusion of the parts.

Plastic identification is the first point to be noted in order to choose a suitable plastic welding rod. A plastic welding rod or thermoplastic welding rod is of a constant cross-section shape. Using this, two plastic pieces can be joined. It may have a circular or triangular cross-section. Porosity of the plastic welding rod is an important factor. Air bubbles in the rod will be created due to its high porosity. This is responsible for decreasing the quality of the welding. So, the rods used must maintain zero porosity. Otherwise, they should be void less. Products like chemical tanks, water tanks, heat exchangers and plumbing fittings are manufactured by using the technique of plastic welding. By adopting this technique, money can be saved.

Using plastic welding, two plastics can be welded together. This type of weld is performed on children’s toys, lawn furniture, auto parts and other plastic equipments which are used daily – both for domestic and commercial purposes. In order to join the thermoplastics, when they are heated an under a particular pressure, this type of welding is employed. In normal practice, using filler material, the pieces are joined together. There are certain occasions wherein filler material can be avoided. Generally, plastic is not durable and has a shorter life span. Natural elements like cold weather, ultraviolet radiation from the sun or continuous exposure to chemicals causing contamination, will create damage to plastic products. Plastic can be subjected to damage if it is hit on a hard surface. But, as the price of new parts is high, it is preferred to repair the existing products.

As there are different types of plastics, we must know which one we are working with in order to find the exact welding material to be used. We must know the difference between thermoplastics and thermo sets because it is not possible to weld thermo sets. If you use the wrong welding rod for the plastic to be repaired, bonding will not take place. As materials like polyolefin’s have a lower surface energy, a special group of polyolefin adhesives has to be used. When you are repairing plastic, there are usually two types of defects – a crack or a broken part. In the case of a crack, there is a particular stress affecting the inside of the material. You have to repair the crack and you should not continue through the piece.

There are many types of plastic welding.

• Hot gas welding uses a welding gun which has electric heating elements. They produce heat f hot gas.
• Hot plastic welding uses a hot plate place between the two surfaces which are to be joined. In order to weld two pieces, ultrasonic welding uses a high frequency acoustic vibration. After subjecting them to high pressure, they are exposed to the vibrations until the weld is completed.
• Spin welding, where friction is employed to weld two cylindrical parts. These parts are rotated. The rotation stops at a particular point and the weld is completed.
• Vibration welding exposes the pieces to a frequency called amplitude. The two pieces are subjected to pressure due to which a friction is created which generates heat.

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Brayan Peter is an expert author for Welder, Plasma Cutter,Plasma Cutting Machine, Tig Welding. He written many articles like Welders, Plasma Cutters, Welding Equipment, Arc Welder, MIG Welder, Welding Machines, Diesel Generators, Welding Helmets . For more information visit our site http://www.everlastgenerators.com. Contact him at weldings.info@gmail.com

Mig welding machines can be broken up into four basics main parts or areas that are very critical to the successful operation of the machine.

The first area I will talk about is the power supply. The power supply on any mig welding machine is a key area in which controls many variables. Some of the “made to a price” mig welding machines are very basic in their functions and abilities. Take for example a small 110Volt or 220volt hobby or DIY type welding machine.

A lot of these machines will be made to run at very low maximum amperage outputs. They will have lower duty cycles and often used aluminium windings in the power sources.

Now lets take a comparative look at a tough industrial high workload mig welding machine like an OTC Daihen XD400 or XD500.

First thing you will notice is the sheer size of this machines power supply compared to that of a smaller hobby welder. The maximum power output will be much higher and this machine will run day and night in a production environment hassle and trouble free. The duty cycle will be much longer and there will also be a better current output from the machine which means you will have far superior weld beads.

The second area is the welding torch, or the mig welding gun. Once again on the lower end of the scale, the welding guns that are supplied with the cheapie mig welders are usually proprietary to that particular brand of welding machine. The mig torch welding consumables will not be as “mainstream” and the quality of the actual welding torch can be of much lesser quality and durability, which will lead to failures and lots of swearing and cursing.

Mainstream mig welding guns will offer higher duty cycles, many more consumable options, longer service life and a wider availability of spare parts and consumables. Also these industrial trade quality mig welding guns will be more comfortable to use which means less user fatigue, they will have smoother feeding resulting in far superior welds and if you are in business the reliability of these torches will save you money.

The third most important aspect of any mig welding machine is the mig welding wire. The mig welding wire is absolutely critical in the mig welding process. Selecting a quality mig welding wire is often very hard to do. Unfortunately people buy mig wire on price and usually price only.

Sadly though cheap things aren’t good, and good things aren’t cheap. This is very true with mig welding wire. The cheap wires will have bad copper coatings, sometimes even being sold with rust on the wire itself. The wire diameter tolerances will not be consistent which will result in irregular wire feeding, which will then result in burn backs, which will then result in having to replace contact tips which cost money and then you loose the production time as workers are walking around fixing welding machine feed problems all day.

The fourth and last critical area on a mig welding machine is the earth clamp or ground clamp.

You have to remember that when you are welding, you are simply creating an electrical circuit. And for that circuit to complete you must have a good earth connection. This can be solved by having an earth clamp that has clean contact faces. Over time little arcs will form on the welding ground clamp which will hinder its operation.

Then if you put the earth clamp onto rust steel or painted steel it will be even harder for the mig welding machine to complete the welding circuit. Resulting in the person welding getting angry because his mig welder isn’t working properly.

For further reading please visit

http://www.learn-how-to-weld.com/mig-welding-basics-1.html

Cheers,

Peter Apalais

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