Welding is commonly used to form a bond between 2 dissimilar materials (however, that isn’t always the case). There are forms of welding that bring materials to their melting points and uses filler metals to form a bond between them. The finished weld, once fully done will blend to be just as strong as the parent metal. Brazing on the other hand, uses a filler metal (alloy) to form a bond between two pieces of metal. Brazing is typically used to form a bond between dissimilar metals such as copper, silver, gold, and aluminum. Flux (a material that’s used to promote wetting) is also used during welding. It cleans parts of the oxides so the filler is able to bond more tightly to the metal parts.
Welding
What is Welding?
Welding joins metals by (typically) using high heat to form a bond between 2 materials (typically some form of metal). As the type of welding varies so will the use of shielding gas and consumable.
Video credits to Kevin Caron, Artist. It discusses how to choose the right shielding gas.
Some forms of welding use filler metals to form bonds between 2 materials (again, usually metal). Each of the forms of welding falls into their own separate categories as well.
Welding is an activity that’s vital to our infrastructure. Welding, unlike other metal joining processes typically melts the base materials together. Typically, a filler material is used inside of the joint which forms a pool of molten material which hardens to form a joint that can be stronger than the parent metal.
Automotive: Since MIG welding is typically used to deliver incredibly powerful bonds between thin metals and is ideal for joining sheets of metal on manufacturing lines.
Aerospace: MIG Welding, Plasma Arc Welding, and Electrical Resistance Welding are all used in the Aerospace Industries. MIG Welding is used to build aircraft while PAW and Electrical Resistance Welding are used for joining sheeting and precision work.
Construction and Infrastructure: MIG Welding, Plasma Arc Welding, and Flux Cored Welding are all used in construction and infrastructure. MIG Welding helps join non-ferrous metals and steel in the construction industries. Flux Cored Welding is also used alongside Plasma Arc Welding.
Manufacturing: Because MIG Welding is known for its cost-effectiveness and speed which makes it great for high-output manufacturing.
Railroads: Shot Welding, and innovative form of spot welding is used for the effective fusing of steel.
Shipping: Welding is used in the development of most ships, from large tankers to cargo ships / aircraft carriers.
industries.
Brazing
What is Brazing?
Brazing is a metal joining process where metals are joined together by melting / flowing filler metals into a joint. The filler metal used in brazing has a lower melting point than that of the parent metals.
Brazing doesn’t melt the adjoining metals used in welding. The filler metals flows into the gaps left between the close-fitting parts via capillary action. It is then brought slightly above its melting temperature while also being protected by a suitable atmosphere. This filler metal then flows over the base metal and is cooled to join both pieces together.
Furnace Brazing: Furnace brazing is a semi-automatic process that’s typically used in industrial brazing operations because of its adaptability to be used for mass production and ability to be used by unskilled labor. A few advantages of furnace brazing are:
It can produce large numbers of small parts easily
It offers a controlled heat cycle and no need for post braze cleaning.
Vacuum Brazing: Vacuum brazing is a joining process that yields various advantages. For example it offers extremely clean, flux free, superior braze joints.
Silver Brazing: Silver Brazing is brazing that uses a silver alloy-based filler.
Dip Brazing: Dip brazing is well suited or brazing aluminum since air is excluded, which prevents oxides from being formed.
Braze Welding: Braze Welding usually requires more heat than brazing does which is why it typically uses Acetylene or Methylacetylene-Propadiene gas fuel.
Torch Brazing: Torch Brazing is a method of mechanized brazing that’s best used in small production volumes. The 3 categories of torch brazing are: automatic, machine, and manual brazing.
How to make sure the surface area is clean during brazing?
When you’re welding you want to make sure that your surface area is clean. The good thing about welding is that the surface area is cleaned by the heat that you produce when you start the welding process – so you don’t need to worry about that too much. However, when you braze you produce less heat so you need to worry more about the cleanliness of the surface area you weld on. The contaminants that aren’t cleaned off of the surface area form into a layer on top of the weld that often turns into a hardened layer that will get in the way of the bonding process.
Video credits to Lucas-Milhaupt. It discusses how to clean the surface of metals.
According to the AWS (American Welding Society) a groove weld is a weld on a work piece surface, between work piece edges, between work piece surfaces, or between work piece edges and surfaces. The actual weld groove is a channel in the surface of the work piece or an opening between two joint members providing space to contain weld metal. There are 9 types of single grooves welds and 7 types of double groove welds. All groove welds – other than square and flare groove welds – require metal to be removed from either one or both faces of the work-piece.
What is G in welding?
When referring to welding position, a number is used to discuss the actual position and an F or G is used to discuss whether it’s a Fillet (F) or Groove (in this case and G) weld. For a better understanding look to the information below:
Flat Position: Is referred to using the number 1 and depending on whether it’s a Fillet or Groove Weld is categorized as 1F or 1G
Horizontal Position: Is referred to using the number 2 and depending on whether it’s a Fillet or Groove Weld is categorized as 2F or 2G
Vertical Position: Is referred to using the number 3 and depending on whether it’s a Fillet or Groove Weld is categorized as 3F or 3G
Overhead Position: Is referred to using the number 4 and depending on whether it’s a Fillet or Groove Weld is categorized as 4F or 4G
So, G refers to Groove weld in welding.
What are the types of groove joints?
The different types of groove joints can be single (meaning one side of the joint only) or double (meaning both sides of the joint). The different types of groove joints are:
V-groove
J-groove
U-groove
Scarf
Square Groove
Flare V-Groove
Flare Bevel Groove
How is a weld groove structured?
Groove welds are made of an arrow line, reference line, a tail, Weld procedure specifications, and a groove weld symbol. Despite popular belief, groove weld symbols can be much more complicated than fillet weld symbols are. Another thing to keep in mind is that groove welds can also be combined with fillet welds.
What are groove welding symbols?
Much like all other weld symbols the reference line of a groove weld is drawn horizontally; it contains all of the weld type information and connects the arrow line as well as the tail. The bottom of the reference point on the groove weld is called the arrow side. The tail of the weld is an optimal element and is where the information for the weld is located.
The rot opening of the weld is used to provide access for the welding electrode as well as improves the penetration of the weld on the work pieces. In instances where the weld gap is insufficient to penetrate the work piece they are angled. One will also only find a bevel in the work piece when it is angled.
What are Groove Welds used for?
Corner Welding Joints
There are a number of corner welding joints. This is one of the most popular welding joints in the sheet metal industry and are used on the outer edges of the piece. This joint comes together between 2 pieces of metal at a right angle to make an L. They’re typically used when making box frames and boxes.
The types of groove joints used to create corner joints are:
V-Groove Weld
U-Groove Weld
Bevel Groove Weld
J-Groove Weld
Flare-V-Groove Weld
Square-Groove Weld
Edge Welding Joint
Edge welding joints are typically applied to sheet metal parts with flanging edges or are placed at a location where the weld must be made to attach to adjacent pieces.
The types of groove joints used to create edge welding joints are:
Bevel-Groove weld
J-groove weld
Square-groove weld
V-Groove weld
U-Groove Weld
Lap Welding Joint
Lap welding joints are used to join 2 pieces with differing thicknesses. A weld can be made on both sides of the metal with lap welding joints. Lap joints are formed when 2 pieces are placed in an over lapping pattern on top of each other.
J-Groove
Flare-bevel groove weld
Bevel-groove weld
Tee Welding Joint
Tee welding joints are formed when two members intersect at 90 degree angle which results in the edges coming together in the center of the plate / component.
The types of groove welds used to create tee welding joints are:
Bevel – groove weld
J-groove weld
Flare-bevel groove weld
Butt Welding Joint
Butt joints are a universally accepted method for attaching pipes to themselves. Butt Welding Joints are also called square groove welds and are known to be the easiest / most common weld. It’s made of two flat pieces that are placed parallel, side by side.
The types of groove joints used to create butt joints are:
Many people think that to earn good money, they need to go to college and get a degree. The reality is that there are a number of real-life positions in the world where you can make decent money and not get a four-year degree.
Take welding for example.
If you were to become a certified welder you could get a certificate in about 9 months and be well on your way to making enough money to sustain yourself. And get this, as you get better as a welder you can charge more.
2. There are a vast number of career paths that welders can choose from
Not only do you not need a college degree to become a welder but you also don’t need to worry about a lack of opportunity in a variety of industries, because there is always opportunity. Welding is one of those career paths that opens people up to a wide variety of possible industries to work in – all you would have to do is pick one and focus on it. Because of the scarcity of welders in the US right now welders are finding themselves working in a wide variety of industries such as:
Sales
Project Management
Education
Engineering
Inspection
Robotic
3. You can be a traveling welder
Another great thing about being a welder is that you don’t have to restrict yourself to one locale either. You can work in places ranging from the ocean all the way to space – how amazing does that sound?
Now, there are a plethora of traveling welder positions, all you would have to do is a bit of searching for them (and with sites like Indeed and Ziprecruiter it’s pretty easy to find them).
Here are a few of the jobs where you could work as a traveling welder and make a decent amount of money:
Underwater Welding
You may not have known this but you can literally work in the bottom of the ocean. As an underwater welder you would have to be a bit more specialized than other welders but you open yourself up to more opportunity than them as well. You would also have the opportunity to travel to places that many people simply haven’t had the opportunity to visit. Due to the fact that it’s such a specialized skill, companies are always looking for underwater welders.
Ship Repair
Here’s a fun fact, many ships have communities that they build for welders to live so that they can keep them on hand. If this doesn’t demonstrate the need that they have for welders then I really don’t know what does. Now, considering the wide variety of ships that need repair you’ll likely spend quite a bit of time traveling on these ships.
Military Support
Our troops constantly require a welder or welders on hand to repair their equipment. In order to secure a position as a military welder the most helpful mode of entry would be to work for a contracting company. These companies send their welders out and require people who specialize in welding infrastructure and military equipment If you have this type of experience it wouldn’t hurt to consider this type of position.
Installing Pipelines
Pipe welding isn’t the easiest welding job in the world. It’s also one of the welding jobs that appear to remain evergreen. As a pipeline welder you’ll have to travel to incredibly remote areas in order to go to your work. Typically the company you work for will pay for all of your expenses and, considering that you’ll be going to some pretty nice places it doesn’t hurt to consider this as a job.
Motorsports
Since most cars have metal exteriors it makes sense for racecar drivers to require a welder right there on the track with them. As a welder for motorsports, you’ll also have to travel from place to place – the good thing is that you’ll be able to travel with a race car team.
4. You will always be in demand as a welder
Since so many people have decided that the college route is the best way to make money in this economy the welding industry has been barren for quite a while. If the above positions and the accommodations that companies make for them doesn’t signal to you that there’s a demand for welders then I don’t know what will. Keep in mind, no position is perfect. There will always be ups and downs. The good thing is that the opportunities that come with welding far outweigh it’s downs.
5. Your salary can be as high as a doctor or a lawyer.
Fact of the matter is that, as a welder you can make quite a bit of money. There are endless opportunities and with skill comes income. Unlike other vocations, welding is a trade where one can make as much as either a doctor or a lawyer – this means that income can sometimes be as high as 6 figures. Considering that income such as this is possible without getting a degree that’s pretty darn impressive.
Underwater welders can make as much as 200000 a year.
Pipe welders can make up to 185000 a year
Military welders can make as much as 200000 depending on where they are stationed at.
6. Welding is slowly becoming one of the best green collar industries
When we say green collar jobs, we mean those jobs that draw the energy industry towards them. Many of us already know this but, there is a growing need for alternative energy sources in the world – the only issue is figuring out which energy source will actually win. Despite what energy source is chosen to fuel the majority of things welders will still be needed to put together the things that will contain and distribute that energy. As long as there’s metal involved welders will be needed.
7. Not all welding requires heat
Despite popular belief, not all welding requires heat. There is a method of welding that’s done in space called “Cold Welding”. This welding process requires 2 pieces of metal to touch without having any coating on them. Cold welding happens when 2 similar materials join without heating or fusing happening on the surface of the object being fused.
8. There’s need for welders in manufacturing
A large number of welding jobs can be found in manufacturing. According to statistics gathered by the U.S. Bureau of Labor Statistics the manufacturing industry employs about 300,000 people in the U.S. The most common businesses who hire in the manufacturing industry are those who ork mining and agricultural manufacturing, structural metals manufacturing, and architectural and structural metals manufacturing.
Unimate was the first industrial robot built, ever. It was equipped with hydraulic actuators and memory so it could perform the hudreds of pre-programmed steps (with position repeatability being at around 1 mm, I might add). Not to mention that this robotic arm, the Unimate, was designed to spot weld.
10. The S.S. Robert E. Perry only took 4 days, 15 hrs, and 27 minutes to build
The fastest a ship has ever been built is 4 days, 15 hrs, and 29 minutes. The ship was buit during WWII and was so done in hyperdrive. It took the shortest time to build than any vessel in the worls at that time (11/12/1942). The funny thing about the S.S. Perry was that it was built so fast only because of a competition that took place between another shipyard.
11. Welders have a median age of late to mid fifties.
This means that pretty soon they’ll have to be replaced. Possibly by you. In fact, according to an internation news organization named Reuters, the median age is actually 55. (this data was also ased on us having 450,000 welders in the U.S. In fact, it’s expected for the welding industry to continue growing by 3 percent from 2018 to ’28.
12. We can use both wet and dry welding methods underwater.
So, yeah you can weld underwater (which is kind of a given). You can also weld underwater using a dry method (otherwise called hyperbaric welding).
Hyperbaric welding is a welding process whereby a person seals a chamber around a structure, fills it with gas, and essentially welds.
The benefits of using hyperbaric welding are that:
A high percentage of manufactured products are made using welding/the skills of welders. This data shows how important welding is to the country’s health economically and that welding is essential to keeping the USA strong internationally and domestically.
14. Explosion welding can almost weld any material together (or should we say dissimilar/incompatible materials together)
Explosion welding accomplishes welding by speeding up one of the materials being welded using chemical explosives. It doesn’t melt the metals being welded but it does plasticize their surfaces so they can blend enough to form a weld. It’s great for bonding large surface areas quickly and creates a relatively clean weld.
*Fun fact: Explosion welding is a fairly new discovery.
The downside to this is that you need some experience with explosives to be decent at this.
15. Welding’s history dates back thousands of years
Welding is a form of technology that dates back at least 10,000 years. Some even claim that before fire was invented, earlier man used hot rocks to develop weapons and tools by melting them together – this is hard to prove though.
During the Bronze Age, people have been said to use tin and copper to develop weapons and tools using smelting. To do this they heated rocks up until they were molten, added some molten ore, and continued to heat it up until it melded with the rock.
During the Iron Age, it’s been said that people who lived near what is now Turkey had a method to make steel and iron by adding charcoal to heated rocks. They would then take what is now a molten mixture and pour it into a mold to make whatever they needed.
16. Back in 1969, welding was first performed in outer space
During the Apollo-Soyuz Test Project in 1969, the first welding test project was performed in space. Special equipment was used to build a helical antenna that made completely of metal while the person who made it, Alexei A. Leonov, was on the Soyuz spacecraft, which was necessary for testing if Russian and U.S. technologies were compatible.
17. The creation of welding helped us invent electricity
Welding wasn’t only used to help us make things; it was also used to find a fundamental piece of nature that’s used every single day. Before the discovery of welding, people didn’t know how to make electricity using electric current and magnetism. Once welding became popular, scientists studied it and found a secret that could be used to harness electricity.
18. To become useful, welding needed electricity
Welding wouldn’t be used to help people develop industries until electricity was invented which happened between 1831 and 1879. Once electricity was discovered, it had to be used to make other devices like motors and generators before welding had any useful applications.
This essentially means that without having invented electricity, there isn’t much that could’ve been achieved with welding. With this in mind, electricity wouldn’t have been found without having already had basic welding processes that were already there.
In the year 1885, the scientist William W. Jacques made a procedure for welding named resistance welding, which harnessed electricity as its main source of heat.
19. Welding was used by humans to make the wheel
Welding was a crucial skill in the making of the wheel. Before human beings knew how to meld metals and make wheels for machines or transportation, we didn’t have a way to use metal for anything. If welding hadn’t been invented, humans may still be using carriages and carts to this day.
Bronze is known as the first metal that was widely used in history and it’s considered to have been discovered nearly 5,000 years ago. Before that, tools were typically made using wood or stone. Having said that, research shows that the Neanderthals who lived in what is now known as France could’ve used metals to make their weapons and tools. It has been stated that there were meteorites that landed in that area during the Stone Age, and some of these meteorites held raw materials.
As you can see welding has a long history and a ton of applications. To view more on welding go to our other articles here.
When we say the word “fusion” we mean the process of applying pressure to 2 distinct pieces of metal to the point that they are one thing. Basically, fusion welding occurs when you weld metals of the same make and same melting points. Fusion welding doesn’t always require the use of filler material either.
Where is fusion welding used?
Usually, fusion welding is done in construction areas on bolts and rivets. When you fusion weld you are heating the pieces of metal until it’s molten and then you allow them to cool until they solidify. Fusion welding can be separated / categorized by it’s being a consumable or non – consumable electrode method.
What are fusion welding processes?
There are a few fusion welding processed. They can all be categorized according the levels of heat they use (and whether they’re consumable or non-consumable electrode processes) such as:
Electric Arc
Gas
Electrical Resistance
High Energy Density
What are the arc welding processes?
Arc welding is a welding process that’ used to create a bond between 2 metals. Arc welding occurs when an electric arc from either a DC or AC power supply creates an intense heat of around 6500 degrees Fahrenheit. Below are the Arc welding processes.
Shielded Metal Arc Welding
What is Shielded Metal Arc Welding?
Shielded Metal Arc Welding is also known as manual metal arc welding, stick welding, or flux shielded arc welding. It’s suitable for welding both non-ferrous and ferrous metals in all positions. However, it’s typically used to weld materials such as Iron and Steel for maintenance and repair industries and construction of heavy steel structures. SMAW electrodes are made up of a stick or a solid metal rod surrounded by compounds and metal powders with bonding agents that help bind the metals to the surface.
SMAW is one of the most popular (and earliest) welding processes because of it’s versatility and simplicity.
Video credits to Weldnotes.com. It goes over what Shielded Metal Arc Welding is.
Metal Inert Gas Welding and Metal Active Gas Welding
What is Metal Inert Gas Welding?
Metal Inert Gas Welding is a welding process where a solid wire electrode is fed through a welding gun directly into a weld pool to join two base metals together. Shielding gasses are then used to protect the weld pool from environmental contaminants such as oxygen.
MIG welding allows everyday people such as artists, hobby welders, farmers, ranchers, motor-sports enthusiasts, and DIY welders to perform welds on metals up to 1/2 inches thick.
Tungsten Inert Gas Welding
What is Tungsten Inert Gas Welding?
Tungsten Inert Gas welding (aka Gas Tungsten Arc Welding) is a welding process that uses a non-consumable electrode (made of tungsten) to deliver the current to the arc. Both the electrode and weld puddle are protected / cooled with an Argon shielding gas (usually). TIG welding also uses a filler material for reinforcement.
Video credits to Weldnotes.com. It goes over what TIG welding is.
Plasma Arc Welding
What is Plasma Arc Welding?
Plasma Arc Welding is a process similar to TIG welding. The electric arc in PAW is formed between an electrode (typically made of sintered tungsten) and the metals being worked on. In Plasma Arc Welding the plasma arc can be separated from the shielding gas envelope. The plasma is then forced through a fine bore copper nozzle, constricting the arc, and the plasma exits the orifice at velocities that approach the speed of sound.
Video credits to Skill Lync. This video explains what Plasma Arc Welding is.
Submerged Arc Welding
What is Submerged Arc Welding?
Submerged arc welding is a welding process that requires a metal core electrode. Both the weld (which is molten by this point) and arc zone are protected from contaminants by being submerged under a blanket granular fusible flux made of manganese oxide, lime, silica, and calcium fluoride. When the flux is molten it becomes conductive and provides a path between the work and the electrode. The thick layer of flux covers the molten metal which prevents spatter and sparks while also suppressing the intense UV radiation and fumes that are an integral part of the SAW process.
Video credits to xAZEZELx13. This video explains what Submerged Arc Welding is.
Flux Core Arc Welding
What is Flux Core Arc Welding?
Flux cored arc welding is a semi-auto welding process that uses a continuously fed consumable electrode which contains a flux and constant voltage (or constant current welding power supply). Externally supplied shielding gasses are used occasionally but more often than not the flux is relied upon to generate a shield from the atmosphere, which produces both gaseous protection and liquid slag protection for the weld.
fun fact: because of it’s high welding speed and portability flux-cored arc welding is often used in construction.
Video credits to Weldnotes.com. It goes over what Flux Core Arc Welding is.
What are the gas welding processes?
Gas welding is a welding process that uses gases and oxygen to weld metals together. There are a few names for gas welding but the most common are oxy welding and oxyacetylene welding. Types of gas welding processes are:
Oxy-Gasoline Welding
When fabrication costs are an issue pressurized gasoline is used a welding fuel. Gasoline torches are sometimes considered more effective for torch-cutting thick steel plates.
Oxy-Acetylene Welding
What is Oxy-Acetylene Welding?
Oxy-Acetylene welding uses a mixture of acetylene gas and oxygen gas to feed the welding torch. Oxy-Acetylene welding is actually considered the most common gas welding technique. The mixture of oxygen and acetylene gasses is known to produce the highest temperature of the available fuel gasses (it’s also one of the most expensive fuel gasses).
Video Credits to We Build Stuff. It’s an intro to Oxy-Acetylene Welding.
MAPP Gas Welding
What is MAPP Gas Welding?
MAPP Gas Welding (or Methylacetylene-propadiene-petroleum) is a gas mixture that’s considered more inert than other typical gas mixtures. This also coincidentally makes it safer for recreational or hobby welders to use.
Video credits to CNC TopNet. It gives an example of MAPP Gas Welding.
Butane / Propane Welding
What is Butane / Propane Welding?
Butane and Propane can be used both separately and together as fuel gasses. Both butane and propane have a lower flame temperature than acetylene but are also less expensive and easier to transport than acetylene.
Propane torches, when used by themselves, behave a bit differently than Butane. Propane torches are also used for bending, soldering, and heating. They also require a different type of torch tip because propane is a heavier gas.
Video credits to my tech trials. It discusses Butane torch brazing, soldering, and welding.
Hydrogen Welding
What is Hydrogen Welding?
Hydrogen gas welding is a welding process that generates welding heat by passing hydrogen through an electric arc that’s between two inclined electrodes. Hydrogen welding can be done at higher pressures than other fuel gas welding processes, which makes it better-suited for underwater welding. The heat produced during hydrogen welding is considered to be enough to efficiently weld Tungsten (3,422 degrees Celsius), which is the most refractory metal.
The hydrogen also acts as a shielding gas which prevents both oxidation and contamination from nitrogen, carbon, and oxygen. It also takes away the need of a flux for environmental shielding.
Video credits to Habibur Rahman. It discusses hydrogen welding.
What are the Electrical Resistance welding methods?
Electric Resistance Welding is a term used to group a number of welding processes that produce coalescence of faying surfaces where the heat to form the weld is generated via the electrical resistance of the materials and the time and force that’s used to hold both materials together while welding taking place. Factors that influence the heat / welding temperatures are:
Metal coating or lack thereof
Electrode materials
Electrode geometry
Electrode pressing force
Electrode current
Length of welding time
During electrical resistance welding small pools of molten metal are formed at the point of most electrical resistance and the same time an electrical current is passed through the metal.
Spot Welding
What is Spot Welding?
Spot welding is a form of resistance welding where two or more sheets of metal are welded together without using any filler metal. The welding process requires the use of pressure and heat to the weld area using shaped alloy copper electrodes which convey an electrical current through the weld pieces. As the material melts the parts are fused together. At this point the current is turned off and pressure from the electrodes is maintained and the joint is formed.
The heat used in spot welding is generated via an electric current which is transferred to work pieces via copper alloy electrodes. Copper is then used for the electrode as it has a high thermal conductivity and low electrical resistance compared to other metals. This ensures that the heat generated is generated in the work pieces rather than the electrodes.
The amount of heat generated depends entirely on the electrical resistance and thermal conductivity of the metal (and the time the current is applied). The equation used to express the level of heat generated is:
Video credits to Jeffrey Santo. It discusses basic spot welding.
Seam Welding
What is Seam Welding?
Seam Welding (aka Resistance Seam Welding) is a type of spot welding that uses motor driven wheels rather than stationary rods. Seam welding is est used for sheet metal fabrication since it passes an electrical current through the sheets of metal to be joined while they’re being held together via a mechanical force in a lap configuration between shaped copper electrodes. Fusion of the two metals occurs where the sheet metal surfaces touch one another – this is the point of highest electrical resistance as well as the point where the heat generation is highest.
Another form of seam welding is the consumable wire resistance seam weld. The difference between this and regular seam welding is that the electrode wheel is grooved so that a shaped copper wire can be placed between the material you’re trying to join and the wheel. Copper wire is then fed from a spool and passed around the electrode wheel at welding speed before it’s discharged into a scrap container. This makes sure the clean, uncontaminated surface is presented to the work.
Consumable Wire Resistance Seam Welding is highly reliable and achieves welding speeds of well over 70 meters per minute.
Video credits to Poor Man Mods. It shows how to seam weld.
Low-Frequency Electric Resistance Welding
What is Low-Frequency Electric Resistance Welding?
A Low-Frequency Electric Resistance Welded pipe is one that’s manufactured via cold-forming a sheet of steel in a cylindrical shape. The electrical current is passed between 2 edges of steel to heat the steel to a point where the edges are forced to form a bond between one another without using filler material. This welding process has become antiquated however and has been replaced by high frequency electric welding process.
Video credits to Rishika Janaki. It gives fun facts about low-frequency resistance welding.
Flash Welding
What is Flash Welding?
Flash Welding is a type of resistance welding process that doesn’t use any sort of filler metal. Pieces of metal are set apart at a distance based on their composition, thickness, and the desired properties of the weld once finished. A current is applied to the metal, and the gap between both metals creates resistance and subsequently creates an arc (which is required to melt both metals). Once both metals reach the required temperature they are pressed and forge welded together.
Resistance Projection welding is a type of resistance welding that uses concentrates force, electricity, and time on projections (raised segments) to join pieces together. RPW can force welds to occur in very tiny, specific locations while also minimizing the dissipation of heat to other metal sheets.
RPW (or Resistance Projection Welding) is typically used in the auto industry, where screw fastener parts (nuts and studs) are joined to metal sheet components. One can also find Resistance Projection Welding in bar and cross wire welding.
Video credits to Supinder Singh. It shows Projection welding for cross welding.
Upset Welding
What is Upset Welding?
Upset Welding or Resistance Butt Welding is a welding process that merges either the entire surface of 2 nearby surfaces or progressively along a joint, via the heat from the resistance to the electric current through the area where those surfaces are in contact. Pressure is then applied before the heating of the metals is started and maintained during the heating period.
Upset welding uses the similar equipment to that used during flash welding and can only be done if the metals being welded are equal in cross-sectional area. The abutting or nearby surfaces must also be prepped carefully to make sure they’re ready to be heated properly. The difference Upset Welding has with Flash Welding is that the parts are clamped in the welding machine and force is applied which brings them tightly together. A high amperage current is then passed through the joint which heats the surfaces. When the heat s suitable for forging an upsetting force is applied and the current is applied. The high temperature of the work at the abutting surfaces plus the high pressure causes coalescence to take place.
Video credits to Maneklaxports. it shows an upset butt welding machine.
What are the High Energy Density welding processes?
High Energy Density Welding is made of welding processes that utilize heat sources capable of proving extremely high-power-density weld input levels. The density of the energy available from a heat source for welding is oft more important than the absolute source energy. Two of the major types of high energy density welding processes are Laser Beam Welding and Electron Beam Welding. Both of these welding processes use a high intensity beam as the heating source for the weld in which the energy from the source is highly concentrated by electromagnetic or optical lenses.
Electron Beam Welding
What is Electron Beam Welding?
Electric Beam Welding is a fusion welding process that uses a beam of high velocity electrons to join materials. The kinetic energy of the electrons is transformed into heat upon impact on surface of the working material. The work-piece and (possibly) filler metal, if used, melts to form a part of the weld. The welding is often done in conditions of a vacuum to prevent dispersion of the electron beam.
Most metals can be welded with electron beam technology, but the most common are:
Superalloys
Reactive and Refractory Metals
Stainless Steels
Electron Beam Welding isn’t limited or controlled by thermal conduction. This allows metals to be welded to one another using high thermal conductivity, or joint designs with asymmetric heat transfer characteristics.
Video credits to Engineer’s Academy. It discusses Electron Beam Welding.
Video credits to EB industries. It goes over the differences between Laser Beam and Electron Beam Welding.
Laser Beam Welding
What is Laser Beam Welding?
Laser Beam Welding is a welding process that joins pieces of metal / thermoplastics by using lasers. The laser beam is a concentrated heat source that allows for the creation of deep, narrow welds as well as high welding rates. This welding process has been automated in several industries such as the automotive industry.
Have you had a welding machine at your home for years and have been wondering what you’re going to do with it? Are you considering purchasing a welding machine for household repairs but don’t know what method of welding you’re going to use to do them? Well, you have quite a few options, but the most feasible would likely be either spot or seam welding. Both of these forms of welding occur when one applies pressure to both of the pieces of metal that they’re seeking to weld together. Both of these forms of welding are considered resistance welding because of the application of an electric current that is sent through both of the sheets of metal which creates heat; this also fuses the 2 pieces of metal together.
What is Spot Welding?
If you’re looking for a method of welding that will allow you to quickly fuse 2 pieces of metal together spot welding will likely be the process that you’re looking for. It’s typically the welding process that people use if they are considering learning to weld for the first time. Spot welding is a method of welding that uses 2 pieces of copper electrodes which are what are used to generate the heat necessary to begin the weld.
Spot welding is great if you’re seeking to weld pieces of metal between the widths of .5 to 3 mms. Spot welding is also typically used to weld sheet metal and wire mesh. The great thing about the process is that it doesn’t require a shielding gas for it to work. On top of that you can use either a special Spot welding machine – we have a guide for them here – or you can use a MIG welder that’s equipped with a kit.
Video credits to Pro Spot International. It discusses the resistance spot welding process.
What are the advantages of spot welding?
Spot welding yields a number of benefits to those who decide to perform it. Lifted below are a few of the benefits of spot welding.
It’s one of the most efficient platforms for welding small pieces of metal to one another.
Doesn’t require filler metal or fluxes.
Doesn’t take a lot of time to learn nor does it require an profound understanding of the activity to perform.
Welders don’t use open flames in spot welding.
Spot welding can weld pieces of metal that are as thin as .25 inches thick.
Spot welding can be used to weld metals through both a manual and automatic method.
Spot welding can weld multiple metals at a single time.
What are the disadvantages of spot welding?
Nothing that yields an advantage neglects to yield a disadvantage (that’s a truth of life). Spot welding is no exception. Below are a few disadvantages native to spot welding.
You’ll need to use a different form of welding for thicker metals because it works best with thin metals.
Spot welding is typically used in a number of industries including aerospace, white goods, rail, metal furniture, automotive, electronics, medical building, and construction. It’s commonly used in places that require high automation since it’s very easy to combine it with robots and manipulation systems.
What is Seam Welding?
If you want to weld small spots but still want to produce sturdy welds seam welding is probably the best route for you to take. A seam weld is produced when both heat and pressure are applied to a joint on 2 pieces of metal. The 2 common types of seam welds are Fillet and Butt Joint welds.
Seam welds use rotating electrodes which are the primary ingredient in producing the solid rolling resistance weld. A cool thing about seam welding is that it can be done with both TIG and MIG welding machines. Despite of it being known for being used for smaller surface areas, it’s also great for when you want to weld large pieces of metal.
Video credits to TechTrixInfo. It goes over how seam welding works.
What are the advantages of seam welding?
Seam welding also yields several benefits such as those listed below:
It produces much less overlap than spot welding does
Seam welding produces welds at incredibly fast speeds and, because it’s entirely automatic is much faster than spot welding.
Seam welding doesn’t require the use of flux or filler material.
Seam welding produces airtight and watertight seals. The benefit of this is that it helps to create metal structures that need either air or water leakage protection.
What are disadvantages of seam welding?
You can only weld in straight lines and uniformly curved lines when you’re seam welding
Seam welding can be a challenge when what you’re welding is too thick (it can be a pain to seam weld when you’re welding a single sheet that’s more than 3 mm thick).
Where is seam welding used?
Seam welding also finds itself being used in a number of areas. For example, seam welding is sometimes used in places that require air-tight seals such as in the assembly of fuel tanks. Seam welding is also used to weld pipes and tubes because it doesn’t use any fusion metals which means there are no weld beads that may ruin the aesthetics of the pipes / tubes.
Seam welding is also used to manufacture sheet metal tanks to contain gasoline, kerosene, and other fluids.
What’s the difference between spot welding and seam welding?
Spot welding is better utilized for welding materials that’re smaller and are overlapping. Spot welding has a manual mode while seam welding does not. Seam welding is great for welds that need an air-tight seal (remember that spot welds tend to not be the best overall. It’s also great for welds that must be continually done such as for placing strings of spot welds.
Many people think that TIG welding is one of these complex forms of welding that is just too expensive to learn. Only one of those assumptions even holds a bit of truth though. It is true that TIG welding can be expensive – if you’re looking at the incredibly expensive TIG welding machines that companies try to sell. There is no need for a new, inexperienced welder to purchase a 1000$+ TIG welding machine – they likely won’t know what all of the bells and whistles on the machine are used for. The good thing is that there are plenty inexpensive TIG welding machines on the market that will do more than fulfill the need of a newbie. These machines are great at welding various different types of steels and alloys; all you have to do is search and you’ll likely be able to find a machine that fulfills your needs.
For the price, this TIG welder is really all that you can ask for. The Everlast PowerARC is surprisingly lightweight when all of its capabilities are considered. Its lightweight design allows it to be incredibly portable and provide its owner with a fair amount of power. This is a great option for those individuals who are interested in both TIG and Stick welding. The fact that it has the capability to double as a stick welder is one of the reasons why it provides it users with such an immense level of value.
Aside from its ability to double as a stick welder it also features IGBT infineon modules, inverter technology as well as has a dual voltage capability. If you’re one of the people who worries about your machine breaking down before it’s supposed to worry no longer – Everlast gives every person who purchases this welder a 5-year warranty.
Pros
Doesn’t have a foot pedal but is lift start capable
Runs for 6-hour intervals
Functions as both a stick and TIG welder
Runs off of both 110 and 220 V
Cons
Doesn’t work as an AC welder
AMICO 200 AMP TIG Torch/ARC/Stick DC Inverter Welder Dual Voltage IGBT Welding
This and the previous model may seem very similar but, they have very distinct differences. This model features an onboard inverter as well as other, extra features that you typically don’t find with a welding machine such as: a work clamp, electrode holder, 13-foot cable. This dual voltage welder also works with both 110 and 230 V.
Typically, when you find a cheap welding machine you assume that the weld it produces will be subpar. The great thing about this machine is that it manages to produce clean, spatter free welds – welds that you sometimes don’t even find on the higher priced machines. This 200 Amp machine welds all types of materials, from steel, mild steel, copper, and stainless steel.
Pros
Gas line included
Lightweight
Portable design
Fully extendable
Cons
Isn’t flux core
TIG Welder, DC, Maxstar 150 STL
The Maxstar 150 is designed to deliver awesome functionality in both the areas of performance and versatility. It can be used on a number of different metal types and can also be switched between both stick and TIG welding modes. Aside from those abilities, it’s also known for being incredibly portable (it weighs roughly 13.7 lbs and comes with a shoulder strap which makes it relatively simple to move around).
Aside from that it also has thermal overload protection, which means that it’s fans essentially reduce both it’s heat and power consumption. The Lift-Arch technology Miller included in this welder’s design also allows welders to work on both low and high frequencies without causing motor damage.
Let’s also not forget that this welder also has an open circuit voltage option which allows the welder to be run continuously and during specific times when necessary.
Pros
It’s incredibly portable
It comes with a remote control which can adjust the welder from more than 5 feet away.
It’s easy for both beginner and advanced welders to use.
It gives you a choice of choosing the right voltage
Cons
When used at high outputs there may be power fluctuations
It doesn’t work well when used on thicker pieces of metal
It doesn’t come with all the power tools you may need
AHP AlphaTIG 200X
The AHP AlphaTIG 200X can be used for welding a number of metal types but works incredibly well on metals like Aluminum and Stainless Steel. This welding machine can be used to produce precise, thin welds on various metal types and can weld Aluminum up to 1/4″ thick and Steel up to 3/8″ thick.
Pros
It has advanced inverter technology
There are both 2T and 4T modes
You can use it right out of the box
It has adjustable output frequency
It offer excellent arc quality
Cons
It has has fans that tend to make quite a bit of noise
Hobart 500551 EZ-TIG
The Hobart 500551 EZ-TIG comes with an easy-to-use interface (hence the name EZ-TIG). All you need to do is power the welder up and select the material you want to use the welder on. It also has a Fan-On-Demand function which allows one to run the fan once it’s needed, which allows you reduce debris and the dust it draws in.
Aside from that, it also has the ability to weld 22 gauge up to 3/16″ thick as well as the ability to switch between DC and AC. It also has the ability to eliminate tungsten and other material contamination through it’s HF start to permit non-contact arc start.
Pros
It has an easy-to-use interface
It has a high temperature shutdown function
To allow for more consistent welds it has infinite amperage control
It has auto-postflow which allows for optimum shielding based on the welding amperage without requiring adjustment or waste.
The Lincoln Electric Precision TIG is a more expensive TIG welder. It is incredibly efficient and is actually designed to deliver enhanced performance. Aside from that the Lincoln Electric Precision TIG welder can switch between both TIG welding and stick welding modes. It also features MicroStar Technology which allows the welder to deliver a low amp start as well as stability during the welding session.
The Lincoln Electric Precision TIG 225 K2535-2 also features an AC auto balance function which allows it to provide higher levels of penetration and cleaning.
Pros
It can complete a duty cycle at low voltage
It can be adjusted for any situation with penetration, cleaning, and pulse modes
Easy to customize design
It has an easy to use interface
F.A.N. reduces power consumption noise, motor wear, prevents overheating.
Cons
It’s a relatively expensive machine
Everlast PowerTIG 250EX
The Everlast PowerTIG comes with a five-amp start for DC and AC low amp operation. This welding machine is incredibly lightweight and portable while also having the ability to be used in a number of welding settings. It has settings that can be adjusted for 2t / 4t operation. Aside from that the Everlast PowerTIG 250EX also features high pulse frequency capability which helps reduce overall heat input and prevent burning or warpage from occurring.
The Everlast PowerTIG also features a 240V receptacle that’s built in and specifically designed for utilization with the Everlast PowerCool 300 water cooler.
It features an improved HF start circuit which reduces maintenance issues
Cons
This welder isn’t designed to weld thicker metals
How do you choose your first TIG Welder?
Video credits to Miller Welds. It discusses how to buy your first TIG welder.
Who says you have to spend thousands of dollars to get a high-quality machine. The machines on this list will likely fulfill all of your welding needs – unless you require a foot pedal or some other higher end welding capability.
We know the thought of taking that first step into actually signing up for your welding courses can be difficult. We’ve been there, we know the pressure that comes with committing yourself to learning a trade as involved as welding the thing about it is that it isn’t the hardest trade in the world to learn, if you take the necessary precautions. Just like learning anything else, learning to weld is as simple as embodying the things that make up a good welder. It’s about working your butt off every single day to engrain the processes that are involved in welding into your mind.
Is Welding School Hard?
This video goes over advice for starting welding classes as well as gives an overview of what to expect when you begin taking classes.
https://youtu.be/5dBnkhApPoQ
Is welding worth it?
The first thing that many people neglect to take into consideration when they begin to weld is the fact that learning takes time. You aren’t going to pick up your first welding machine, load it with filler and be the best welder in the world. That isn’t how it works.
There are various approaches that students take when it comes to welding. The key is making sure you are determined to learn and get better at welding. Without that determination you won’t be able to stick through the hard parts of the process and reap the fruits of your labor
How to make welding school easier
1. Learn hands on
As with most activities that require motor skills welding is something that is best learned through actual practice. You have to weld and actually make mistakes in order to understand what you should and shouldn’t do when you’re welding- that’s really the only way to learn to weld. Make sure that the area you choose to learn in (school) is packed with welding equipment rather than going to a place that puts emphasis on teaching you theory.
2. Have good teachers
Having a teacher that actually knows what he or she is doing is a key component to eliminating the learning curve that typically comes with welding. Make sure that when you choose your teacher that he or she has both a skill for the trade and actual hands-on experience performing the art of welding. If they don’t possess both of these qualities, then you will likely waste both a fair sum of money and time learning from someone who doesn’t know what they are doing.
3. Work outside of school
You can’t just step into the classroom, do some work, leave, and expect to be good at welding. If you want to be good at welding, you have to live and breathe the trade. You have to do work outside of your allotted time in the classroom; you have to be fully committed to the act of learning to weld. This means that you’ll be taking on outside projects and rehearsing the same activities over and over again until you get it. Also don’t think that you’ll just get your certification and be finished learning, you won’t be. You’ll have to constantly get updated on new welding processes as well as keep yourself knowledgeable about the old ones. It never stops.
4. Be patient
As the aforementioned processes suggest you’ll have to put in actual time in order to get good at welding. It doesn’t happen overnight. With that in mind, you’ll have to focus on the progress you’re making as a welder rather on the things that you’re messing up on during your time practicing. It’ll make everything much simpler in the long run.
5. Have good supplies
A welder is only as good as the supplies he/she keeps. You can’t expect to produce good welds if you are using subpar materials. If you want top of the line welds, as well as want to be protected, you have to make sure that you have everything you need. If you want to know about the best gear on the market right now, click here. We have compiled a list of all of the best helmets, welders, gloves, etc. in order to keep you safe and efficient.
So, does this make welding school worth it?
Well (and this answer may not apply for all) let’s ask Adam Leese.
What good is a review of Welding Torches or Plasma Cutters if you don’t understand why you would need either of them in the first place?
Both of these pieces of equipment serve their own individual purposes, to cut metal. Before you go out to purchase it’s important that you make careful calculations that will allow you to make the most out of the equipment of your choice. Remember, both Plasma Cutters and Welding Torches have their own unique benefits, costs, and supplemental safety equipment that come along with using them.
How to choose whether to use a plasma torch or a welding torch?
Do you require a tool for only cutting or do you also require a tool for brazing, heating, or welding?
What types of metal do you typically cut?
What’s the thickest metal, you ever see yourself cutting with the tool?
Video explaining difference between Oxy-Acetylene Torches and Plasma Cutters
What is a Plasma Cutter?
To answer that question, we should know a bit about the material plasma. Plasma welding is a process that uses an ionized gas (or plasma / electricity or energy in an electricity neutral gas such as compressed air). The elements mentioned in the parentheses (electricity neutr.al gas and electricity) are forced through a nozzle and electrode which makes the (at this time just gas) become imbalanced and. into plasma.
When do you use a Plasma Cutter?
Choosing when. you use a plasma cutter (or the type of cutter you need) depends greatly on a few things such as:
Plasma Cutters are used to cut and gouge, on average materials with a thickness of an inch.
Benefits of Plasma Cutters / Using a Plasma Cutter
All that many understand about plasma cutters is that they cut metal; many don’t know that there are also a vast number of benefits to working with a plasma cutter.
The benefits of using a plasma cutter are:
They’re becoming more and more portable with improvements in inverter technology.
Are very precise with their cuts and require very little clean up (little slag and narrow kerfs)
When you use a plasma cutter under water there is very little heat exposure and very little noise.
Plasma cutters tend to cut quickly.
Plasma cutters can cut non-ferrous material such as cast-iron, aluminum, and stainless steel.
Plasma cutters tend to cut faster on thinner metals.
Disdvantages of using a Table Plasma Cutter:
The upfront investment of plasma cutters is a bit much relative to oxy-acetylene torches.
There are safety hazards associated with using a plasma cutter (as with anything)
What is Oxy-Acetylene Welding/Cutting?
Oxy-fuel welding is a process that uses a fuel gas to cut metals. It was first used in 1903 and was done by using a welding torch. In the process the flame temperature is increased using pure Oxygen which helps the metal you’re cutting melt locally.
For Oxy-Acetylene cutting in particular the torch is used to heat the metal up to what is called it’s kindling temperature. After that, an oxygen stream is trained to the metal, which burns it into a metal oxide and flows out of the cut as slag.
Benefits of Welding Torches?
The most common type of welding torch is the acetylene torch and it uses the a combination of oxygen and gas to develop the heat that will be used to cut the metal. There are several benefits to using an oxy-acetylene welding torch but the most reasonable one is the fact that they are incredibly portable and much less expensive than other equipment that’s used for cutting metal. The portable design of welding torches makes them incredibly versatile and gives them the ability to be used on a variety of different tasks that require metal working such as pipe fitting and motorcycle building.
Differences between Oxy-Acetylene Welding Torches and Plasma Cutters
Function of Plasma Cutters and Welding Torches
If you’re planning on using a welding torch you have to make sure you’re going to have the time you need to be able to cut properly. There is also a bit of preparation that comes into play when you’re using an oxy-acetylene torch, such as the preheating of the metal. You’ll also have to make sure that of things such as:
The gas you use (because the gas has a direct effect on the quality of the cut) is very important to pay attention to.
On the other hand, plasma cutters are able to cut through metals a bit more efficiently than welding torches do. This means the cut provided by plasma cutters is both faster and cleaner than that of a traditional welding torch. You also don’t have to worry about preheating a plasma cutter because of the hotter wave of heat that you’ll encounter when using them.
Prices of Plasma Cutters and Oxy-Acetylene Welding Torches
Depending on how active you are with your metal work, the prices of either of these tools will work fine. For example, if you tend to go through a decent amount of metal in a period then it makes sense to purchase a plasma cutter because of all of the savings you’ll receive. We don’t want to forget that with a plasma cutter you’ll be required to pay a bit more up front than you would with a torch (you would have to pay for things such as the gas). If you don’t cut as often as others a simple welding torch may be all you need to get going.
Here are the prices and relative specs of both plasma cutters and oxy-acetylene torches.
[table id=97 /]
*note: don’t compare each price side by side – this is just to give you an idea of the costs of each piece of equipment. And the number of products was chosen so you could have a broader view of the price of each product.
In conclusion, there are quite a few benefits to using either of these tools. The trick is to find the piece of equipment that will work for you both today and tomorrow. And as always, let us know if you have any questions.
A typical question that we get when it comes to welding mild steel is whether or not it can actually be welded. The short answer to that question would have to be, yes. It can be welded.
There are 2 basic types of wire that one can use to weld mild steel. On the one hand, we have ER70S – 3, an AWS classification. This type of wire is mainly used for all-purpose welding. The thickness of the welding wire that you decide to use will really depend on the type of material that you’re welding. A good, kind of neutral material to use would likely be a .03-inch diameter wire – it would be great for welding metals of a wide range of thickness and purpose.
Welding Positions: an all position wire that supports single and multi pass welding
How do you know if you’re welding mild steel?
For all intents and purposes mild steel can simply be regarded as steel with a very low amount of carbon in it’s makeup. It’s a very simple material to form and is also very common when it comes to MIG welding.
How do you choose a brand for welding wire?
The first thing to make sure of when you first start even considering purchasing welding wire is the quality that you want. If you want a high quality welding wire then you will likely require wire that meets the AWS standard for welding wire.
The AWS standard requires that wires meet a certain level of thickness and have a certain degree of tensile strength.
Where do you store welding wire?
Again, if you think it’s a good idea to buy welding wire then you likely understand that you will need a place to store it.
The most important thing to keep in mind when you’re looking for a place to store your welding wire is that it’s protected from the harmful material in the atmosphere. Keep your wire out of damp environments as this will cause it to oxidize and likely be rendered unusable over time.
The reason that you want to make sure your wire is protected is because it will likely not be possible for it to work correctly if it’s faulty and installed back into your welder. Faulty or rusted wire will likely lead to welding failure in the future.
How do you choose the right size for your welding wire?
There are really only 3 things that you want to make sure you pay attention to when sizing your wire.
You want to pay attention to is the size welding wire that your machine can take.
You want to make sure the wire is the right wire for your machine. Don’t buy flux core wire if you’re using a MIG welder.
Make sure that the wire you use has a thickness that is proportionate to the material that you’ll be welding. If you’re welding a thinner metal, then you likely want to make sure that you use a thinner wire. Vis Versa for thicker metals.
Many think that the most important part of the welding process is the actual welder. We’re sorry to tell you this but, it’s not. The accessories that you have are a key part of keeping you in the game when it comes to welding – we just tend not to think about this important fact. Why do we say this? Have you considered the effect that any welding process would have on your eyesight if you didn’t have a pair of welding goggles? Or even a mask?
This guide will introduce you to the factors that should be considered when you begin your search for welding gear.
What factors go into buying welding accesories?
Where are you going to be welding?
A factor that many simply don’t take into consideration when they begin searching for welding gear is the actual place where the welding will be done. The gear you bring when you’re in a welding shop is completely different from the gear you’ll need if you’re doing the welding outside surrounded by other individuals. What do we mean? Well, if you’re in an actual welding shop, then they will likely have the necessary equipment to keep others safe from the hazards accompanied by welding – there will also very likely not be as many people in the surrounding areas.
If you’re outside you’ll likely need to buy your own welding curtain or something of the like to keep others safe from your welding.
Video credits to Howcast. It goes over a way to set up an indoor workshop to weld in.
What welding process will you use?
There are various different methods involved in welding, each of which involves different types of accessories. For this guide though, we will stick with gas welding – an activity that requires ventilation masks so the wearer doesn’t deal excess damage to their lungs.
Size of the item / welding space
As a prerequisite one should always consider the size of the item they are considering purchasing. If it doesn’t fit, then you will likely not be able to enjoy the benefits that it’s meant to provide. Outside of the wearable products one should consider the space they have available for the item – this is another major consideration to keep in mind when it comes to the size of the item. If you purchase an item that it is too large for the available space then you will have to go through the process of switching it out and returning – it’s probably best that you measure the space you have available before you decide to purchase anything.
Durability
Of course, you’ll want to make sure that whatever you’re purchasing is going to be able to stand the tests of time (and excessive use). The best way to do this is to pay a great deal of attention to the type of materials that the equipment is made of. Another easy way would be to look at comparison reviews of the item you have in mind – this is an easy way to gauge the longevity of an item in comparison to another equally valuable item.
Budget
Regardless of your income you want to make sure that the item you purchase will be able to fit inline with your budget. For the majority of welding accessories (unless you purchase the best items available, in which case you have to expect to spend a pretty penny) you won’t have to spend a ton of money. In fact, on most of the items you can expect to spend surprisingly small sums of money.
What type of Welding Accessories
Facial Protection
If you don’t have facial protection, then you likely don’t understand how dangerous welding can seriously be. Despite the exposure to harmful gases and bright lights, you have to worry about a whole plethora of other potential hazards (hazards that we will discuss in another post). Now, to avoid these hazards it’s probably best that you purchase equipment to keep you out of harm’s way.
Safety Goggles
There are various names for them but, for the most part they are known as welding goggles. These handy little tools are the key to making sure that your eyes are safe from sparks and any debris that your face may come into contact with during the process. These tools are also very good for keeping gasses out of your eyes during the weld as well.
Welding Helmets
Some people think that getting a pair of welding glasses is all that you need in order to stay safe – we’re here to say that there is literally no truth in that. A pair of welding goggles will keep your eyes safe but, a welding helmet will keep your entire face safe.Welding helmets keep the skin on your face safe from shrapnel and from the possible damage the gases can have on your face.
*the above photos gives examples of injuries that when the body is unprotected near a blast site / combustible objects / flying objects and welder’s flash.
Hand Protection
While all welding gloves are simply called “Welding Gloves”, they are all made with different purposes in mind. There are gloves made specifically for TIG, MIG, and Stick welding. Each of which will be broken down in subsections.
MIG: MIG welding is a process that is known for producing a fair amount of splatter as well as for generating a decent level of heat. Aside from this, MIG welding is also known for giving operators more dexterity since users are able to operate a welding gun equipped with a trigger that ca activate / deactivate the process. For this reason, many MIG welding gloves are made of denser leathers that are capable of handling more heat.
TIG: TIG welding has been said to produce much less heat than MIG which implies that one should be able to use much thinner gloves.
Stick: Much like MIG welding stick welding is an activity that is known for producing a high level of heat – which means that the gloves one uses must be relatively thick and capable of preventing your hands from being burned.
Protecting the torso
Aside from welding gloves other parts of the body, mainly the torso, will need to be protected. The common accessories made to protect an individual’s torso are aprons and jackets, as these are the objects that will provide the most protection for this part of your body. When purchasing either of these accessories it’s important to pay attention to the materials that they are made of. Much like the MIG welding gloves that we discussed in the above section, you’ll want to make sure the welding gloves you choose are designed from a thick leather – otherwise they will get burned through and won’t help much (since they’ll expose your hands).
Ventilation
When you’re TIG welding, you want to make sure that you have respiratory equipment, aka breathing masks and things of that nature. If there isn’t proper ventilation in the area that you weld in then you will likely inflict permanent damage on your lungs (something that no one wants to happen).
There are various different pieces of equipment designed specifically to provide respiration while welding – each of which will be covered in a later review by us.
Welding Shield
As we mentioned earlier in the review, it’s imperative that you make sure to purchase a welding curtain of some sort if you weld in a completely open space. This will make sure that your welds aren’t causing immense damage to those around you.
The purpose of this guide is to inform you of the specific materials that you’ll need (and are commonly used) to continue to weld efficiently. Depending on the type of welding you’ll be engaging in you’ll need different things – but that’s what we’re here for, to make sure you make the most informed purchasing decisions.
