Welding is much more than taking two joints and soldering them together. It’s a precise trade that requires proper training and education to perform safely and accurately. There’s nothing “simple” about welding and, in fact, it can be quite a dangerous undertaking. Considering this, welding safety, including proper gear such as welding helmets, is vital for getting the job done right.

The process of welding is especially dangerous for the eyes. This is so for several reasons, including the brightness of the arc, the ultraviolet and infrared rays it emits and the fact debris can sometimes fly loose. Inasmuch, no smart welder gets started without a good helmet.

Knowing you need a welding helmet and choosing one that’s appropriate for you can be two different things. The sophistication of the helmet needed will, of course, depend on the type of welding being done and how often you need it. If you just need to do a solder once in a while, a basic helmet will do. A pro, however, will likely want a more sophisticated piece of protection.

Here are some features to look for in a helmet:

* Comfort. A welding helmet should be comfortable to wear and lightweight. If it’s not comfortable, or reasonably so, it can get in the way of the job, which can lead to accidents.

* It should be easy to use. A helmet should not be so difficult to use that welders try to avoid them or go without them when making a solder.

* Visibility. Being able to see what you’re doing while working a weld is vitally important. The helmet should not block all fields of vision.

* Degree of protection. Welding shields must block ultraviolet rays to be considered effective. These are not sunglasses and the arc you’re dealing with won’t even begin to compare to a 100-watt light bulb! They should also block infrared wavelengths.

The type of helmet necessary will depend on the job being done and the kind of weld being made. Depending on the materials, lung protection might also be needed as some fumes created during the welding process are toxic. There are some other features welders can look for in a helmet to help them with more advanced jobs. They include:

* Auto-darkening helmets. These are great for shop situations where being able to see more clearly when the arc hasn’t been struck is important, but taking a helmet on and off isn’t always practical.

* Solar and battery powered helmets. These help control the auto darkening features on some helmets and some other processes as well. Either is suitable, as long as a solid helmet is chosen.

* Fixed and variable shades. The fixed offers a single darkness factor on the shade, the variable allows different settings to be chosen.

* Other features in helmets can include: adjustability to make it easier for a person who wears glasses to find a comfortable fit, sensor bars to assist in determining when a helmet’s features should be automatically turned on, curved shields and so on.

The key to welding and doing it safely is to not only understanding the process and the equipment, but to also have a good helmet. The helmet is vital for protecting the eyes and the face from harmful light rays, burning and flying debris.

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Robotic welding has come of age in the past few years. In advances in computer technology and robotics, simple, repetitive tasks in manufacturing are often performed by robotic welding devices, with a resulting savings in labor and an improvement in safety, since there is less human interaction and less chance for human error.

Trade shows and conventions for the fabrication industry and welding trades often feature robotic welding devices these days. Demonstrations at the trade shows give examples of robotic welding machines doing graceful and complex maneuvers, demonstrating speed and flexibility possible with robots today that were not possible a generation ago.

Industrial robots are used in welding, painting, ironing, assembly, palletizing, pick and place, inspection, and testing of products. Robots have proven themselves to be valuable resources in manufacturing applications in all of these areas.

Any welding task is suitable for automation if the task is repetitive. From a practical, financial standpoint however the number of pieces that need to be welded must be of sufficient quantity to allow a continuous flow, to justify the initial expense of setting up robotic welding machinery. In such instances an automatic welding gun can be placed in a static position or if needed on a curved track to achieve a circular weld. In this type of situation, a work piece can be rotated past the welding gun.

The major manufacturers in three basic sizes offer robotic welding arms. These include a tabletop size with a six-pound payload, a medium sized model with a 13.2 pound payload and larger machines with a 22.2 pound payload. While these robotic welding machines are available new, many used and reconditioned models are also available and popular.

Where robotic welding machines, and industrial robots in general came from is of interest. The first industrial robot, used for simple tasks, was invented in 1962. In 1969 a Stanford University professor developed the Stanford arm, an articulated robot that widened the potential of robots, making robotic welding possible and feasible. By the 1970′s industrial robots were firmly rooted in most industries and robotic welding’s strong points had become obvious to industry. Soon large companies like General Electric and General Motors were manufacturing robots, and several companies n the U.S. stated specifically to manufacture them and market them to industry, including Automatix and Adept Technology, Inc, while Westinghouse Electric Corporation acquired Animation, the grandmaster of industrial robotics. Many Japanese companies also entered the arena.

Today’s popularity of industrial robots, and in particular of robotic welding devices is due to the fact that these machines save man hours, allowing skilled human technicians, including welders, to concentrate on more complicated tasks worthy of their skills and training. Simple and repetitive tasks that would be a waste of a skilled welder’s time are generally handled by robotic welding machines with cost savings in the millions every year, benefiting the companies and stockholders.

Overall, Robotic welding is one of the most advanced computer technologies and robotic welding devices save in labor and an improvement in safety, by reducing human error and human tragedy.

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2 of 5 from “Welding” on Modern Marvels from The History Channel. Half science and half art, the ancient technology of welding is integral to modern life. It is the process of bonding, as simple as banging two metals together or as sophisticated as interlinking molecules with sound waves, and without it, the modern world around us – from cars to buildings to pipes that deliver clean water – would not exist.

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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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