Find out how to get a start in welding, what tools and skills you’ll need, and how to work in different environments in this article about working as a welder.
If you are new to welding or want to make it your career, this welding manual is for you.
What Is Welding?
At first glance, it seems like a simple process: two metals are fused. As simple as it may sound, there are several techniques for the weld.
The most common process is arc welding. It is easier for beginners and includes stick weld electrodes, shielded gas arc welding, and shielded metal arc welding. It’s practical welding methods that are widely used in industry.
Welding methods are described in more detail below.
Stick Welding
Stick welding is also known as shielded gas arc or SMAW (shielded arc metal welding). The process belongs to the oldest by far and is widely used as it is very simple. Unlike TIG and MIG (metal inert gas) welding, which uses a gas cylinder, there is no influence from the wind. For this reason, a popular selection when welding for outdoor applications.
The Fundamentals of Stick Welding
Stick welding is the creation of an electric arc in the gap between the metal electrode and the workpiece. They are melted by the electric current passing through the electrode, forming a weld pool on the part. To protect against corrosion and environmental contamination, flux is applied to the solder bath (the weld pool) to melt the electrode.
This is similar to TIG (tungsten inert gas) and MIG welding, in which the weld is protected by protective (shielding) gas. When a flux melts, it forms the slag layer over their weld bead.
A fluxing agent is melted over the weld bead. When the weld has cooled, this protective layer should be removed. As for the weld puddle, it is the local volume of metal contained in the weld before it solidifies as weld metal. When heated, the molten metal floods the hole, forming a pool of weld. The latter is an atypical term for a weld.
Advantages and Benefits of Stick Electrode Welding
The key advantages of stick electrode welding can be summarised as follows. Stick electrodes can weld relatively thick metal parts. The weight of the hardware is low, which makes it easy to transport the equipment to different locations. A wire feed welder or other aids, such as a gas cylinder, are not required.
Stick electrode welding is best suited for outdoor welding. Gas welding technology is inappropriate for outdoor use, especially in strong winds. While easier than TIG, mastering wire welding takes some practice.
Stick electrodes can be used as well to weld surfaces that are not completely clean. Can be used on metallic surfaces with light rust or scale.
Disadvantages
Stick electrode welding is more skillful than with a MIG welding machine. This is because the electrode is to be kept some distance away from the workpiece while melting.
Stick welding produces more slag and spatters, and this may hinder this process.
The slag has to be cleaned, which reduces the efficiency. Compared to TIG, this weld is not so robust or of good quality.
How to Get Started in Safe Welding: Basic Safety Precautions to Follow
Before you start welding, recall that your safety comes first. It should take precedence over everything else.
With the help of any welding hardware you use, always read the instruction manual before use. Be sure to follow the safety regulations of the machine manufacturer.
Appropriate safety hardware must be worn for UV protection against radiation, warmth, and sparkles produced by the arc. Keep yourself protected with a shirt with long sleeves clothing made of fireproof material. Safe to wear glasses and/or a safety headgear kit to shield your eyes as well as your head.
When welding with the rod, strong fumes are released by the flux. Therefore, make sure that the area where you work with stick electrode welding is well-ventilated. No have to worry about ventilation while welding outdoors.
However, good ventilation in welding indoors production zones is an effective security feature. An exhaust system should be installed to remove fumes.
Welding machine
A multi-purpose welder is good for beginners. It allows training in a variety of welding methods, like stick welding, TIG welding, and MIG welding. It is also more economical to buy a special machine for stick welders.
Earthing clamp
Included with the welder is also a pair of grounding pliers. Attach the earthing tongs onto a MIG welding machine and apply them against the metal part being welded.
Remove slag
For stick welding, the workpiece is covered with slag, which is supposed to be removed from the weld claw after the weld has cooled sufficiently. A slag tip and a hammer are used to remove the solidified slag.
Selection of electrodes
Different a type of there are available welding electrodes for sale. The most appropriate electrode should be selected depending on the project requirements. 7018, 6013, 6012, 7024, 7014, 6011, and 6010 are the most commonly used welding electrodes.
The type of electrode to be welded, for example, E70 is suitable for joining structural steels (type of welding). Electrode 7018 is preferred because of its good weldability, and electrode 6013 is recommended for novice welders.
To find the right stick electrode, you need to know the meaning of these for numbers.
The lowest breaking strength is indicated by the first two digits. For example, an electrode that begins with 60 is rated with a tensile breaking strength of sixty thousand psi. A value should be consistent with that of the basic material tensile strength.
Number 3 specifies the welding positions in which the electrode can be used. The numeral 1 means that the component can be operated in all welding states. The number two means that the electrode can only be used in a certain welding position – horizontal.
The number 4 indicates the current allowed for the electrode (its sheath). How the digits are constructed is given below. The type of sheathing follows the numbers.
The type of welding is indicated in brackets:
- 0 – sodium content of the pulp (DCEP)
- 1 – cellulose potassium (DCEN, DCEP, AC)
- 2 – titanium dioxide sodium (DCEN, AC)
- 3 – potassium titanate (DCEN, AC)
- 4 – titanium dioxide iron powder (DCEN, DCEP, AC)
- 5 – low hydrogen sodium (DCEP)
- 6 – low hydrogen potassium (DCEP, AC)
- 7 – powdered ferric iron oxide (DCEP, AC)
- 8 – low hydrogen iron oxide (DCEP, DCEN, AC).
Stick Welding Setup
Electrode setting for arc welding is a relatively easy task, as the unit itself is fairly straightforward compared to other types of welding units. Note that the polarity setting depends on the type of welding electrode used. Always ensure that the polarity is DC+/DC/AC.
For practice purposes, it is recommended to start with 6013 electrodes and apply DCEN to a steel plate about 3/16 inches thick.
Apply the First Weld
You can Start welding as soon as the welding machine has been set up as required by the instruction manual. Please verify all the configurations again to make certain that it is correct. Several pieces of 3/16″ thick metal can then be positioned to make a butt weld.
As joining a butt weld requires a defined amount of skill, it is highly recommended that you practice with scrap steel first before attempting any welding projects. Practice until you feel confident and comfortable performing butt welding.
The hardest part of any welding operation is often igniting the electrode to produce the arc. This step is mastered with a lot of practice. But the rest of the welding is relatively simple.
MIG Welding
MIG welding is also known as Gas Metal Arc Welding. MIG is short for Metal Inert Gas Arc Welding. Because it’s the easiest process. for beginners to learn, GMAW is very popular. Can be used to weld car parts and do-it-yourselfers. Low alloy steels are often joined using MIG welding.
Arc welding takes place with an electrode between it and the workpiece. This causes the wire electrode to melt progressively, creating a welding seam.
By connecting a GMAW welder to an electrode gun, the wire electrode can be efficiently and precisely fed. Additionally, the MIG gun delivers a regulated amount of shielding gas to protect the weld pool from contamination.
Mig Welding Benefits
Efficiency
A major advantage of the GMAW process, apart from the easy handling, it’s high productivity and low harvesting costs. Since no electrodes have to be changed and no slag has to be removed, a lot of time is saved. Compared to stick electrode welding, MIG welding has the potential for increased productivity due to its low cost and reliable nature.
Low costs
A reliable MIG welder can be obtained for a relatively low price ($500 or less for the Hobart GMAW 500559 welder), and only a minimal amount of additional expenditure is required to buy gas and wire electrodes. This makes MIG welding an attractive proposition for those wanting to increase their welding productivity.
The increase in productivity described above reduces the cost of welding even more. Ideal for small businesses.
Installation and learning made easy
GMAW is a process that anyone can learn immediately. For this reason, GMAW is the first choice for hobby and home welders. A MIG welder can be set up and ready for use in a matter of minutes.
High quality
GMAW uses a shielding gas to protect the weld metal from environmental influences. The result – reliable and clean welds.
No removal of solidified slag is necessary. In addition, welding can be very precise because the MIG welding gun can be guided with both hands. It is also possible to vary the feed via the pulling force, which makes the process very flexible and highly adjustable.
MIG welding wire
The MIG welding wire must be inserted correctly in the welding machine so that it can feed the wire into the weld.
Size of the wire
Welding machines are sometimes equipped with flux-cored wire coils. GMAW requires a thicker wire. This allows thicker metal parts to be joined together.
The thinner wire should be used to achieve the best welding quality. Here are some guidelines for choosing the wire.
0.23-inch wire – This wire is only suitable for welding small MIG seams and for welding thin metal sheets with a thickness of 16 to 24 mm.
Wire with 0.3-inch thickness – MIG welders are often supplied with wire of this thickness. This wire is suitable for welding thin sheets up to 1/8 inch thick.
0.35-inch wire – This is a good wire for beginners. It can be used to weld sheets up to 1/4 inch.
0.45″ wire – This wire is often the best choice for industrial welding. It is suitable for welding metal parts thicker than 1/4 inch.
Welding gas
MIG welding requires a shielding gas to prevent corrosion of the hot weld metal. The most important properties of the shielding gas are briefly explained below. It also describes how to select the correct shielding gas for the project at hand.
Permeability
Porosity is the appearance of holes in the weld joint. This defect should be avoided as holes are a weakening of the weld and a detriment to the reliability of the weld.
Pitting is often caused by air gases. Therefore, the weld is shielded from damaging substances from the atmosphere with shielding gases. Without the use of shielding gases, a reaction of the weld with the nitrogen and oxygen of the atmosphere is the result and porosity is the consequence.
This is not a problem with flux-cored electrodes, as the shielding gas escapes from the flux-cored electrode and protects the weld pool.
To obtain a strong and reliable weld without porosity, it is best to ensure an optimum flow of shielding gas from the gas cylinder.
It is not advisable to allow too much shielding gas to escape from the gas cylinder. This can lead to a drop in the melting temperature of the weld. A balance must be found between a sufficient gas flow and a high temperature.
This can be achieved by holding the hand at a distance of 5 cm from the nozzle tip. The gas flow is increased. When you can just feel the gas flow on your hand, the ideal gas flow has been achieved.
Protective gas types of welding
The most common shielding gas mixtures are listed below.
Argon pure
Pure argon should not be used for welding steel. For non-ferrous metals such as aluminum, this gas is suitable. Argon is characterized by low thermal conductivity. This makes the weld narrower. Although good penetration is achieved in the center of the weld, penetration in other areas of the weld may be inadequate. For this reason, this product is not suitable for steel.
Carbon dioxide
Carbon dioxide is suitable because it is much cheaper than argon. For this reason, it is widely used and popular among MIG welders.
However, there is one major problem with carbon dioxide. The arc that is created is quite wide and less stable. That’s why it sputters and sputters.
Argon mixture
Welds of the highest quality can be produced with a suitable mixture of carbon dioxide and argon. Pure carbon dioxide and pure argon are the properties of the arc. The arc has the correct width, good penetration, and minimal spatter.
Metal inert gas process
In MIG welding, the following motions occur most frequently.
Straight impact/impact motion
The most common technique used in MIG welding is to advance the weld in the direction of the welding tip. The welding gun must be set at an angle of 10 degrees to achieve the optimum position for MIG welding. The electrode must be aligned in the welding direction. The angle can be reduced to change the shape of the weld.
When the MIG welding gun is correctly aligned, pull the trigger and move it slowly. Press the trigger and move the MIG gun slowly to weld the seam.
Backhand/Pulling
In this position, move the rear hand of the weld gun towards the body. Do this at the same angle as described above for the angle. This procedure achieves a greater welding depth than pressing the electrode.
TIG Welding
TIG is the abbreviation for Tungsten Inert Gas Welding. This welding method involves creating an electric arc with a tungsten electrode, which warms the metal to its melting point. To protect the weld pool from the atmosphere, inert gas is directed over the weld pool. The highest quality welds are produced by TIG welding.
As the user has to hold the welding torch and feed the filler metal with one hand, TIG-welding is the most difficult welding process to master, requiring a high degree of manual dexterity and two-handedness at the same time.
The TIG welding is carried out using electrodes, which do not wear out and are very stable. It may be necessary to use a filler metal, which is added by hand to the electrode. Both the weld pool and the electrode are protected against corrosion by a protective layer. TIG welding provides accurate seams and is suitable for many metals.
Gas tungsten arc welding is a very versatile welding process. It can be used on a wide range of metals including stainless steel, mild steel, nickel alloys, aluminum, chromolybdenum, copper, magnesium, bronze, brass, and even gold.
The absence of flux eliminates the risk of corrosion due to flux inclusions. There will be no slag formation. Therefore, no cleaning is required after brazing. It is also a safer alternative to MIG and stick welding because it produces no sparks or hazardous fumes.
TIG is best suited to applications where appearance is important because it produces clean, high-quality welds. Spillage is avoided as relatively little filler material is needed.
Electric arc welding can be maintained at temperatures of up to 11,000 degrees Celsius due to the favorable thermal properties of tungsten. Tungsten does not melt due to its excellent thermal conductivity and high melting point. It is also far stronger than steel in terms of strength.
TIG welding techniques
TIG welding is performed in 2 types of operation: automated welding and a semi-automated mode. In TIG welding, the gas flow and current settings are configured by the operator in semi-automatic mode. The filler material wire and tungsten electrode are then controlled by the operator.
In automatic mode, the operator configures the gas flow rate, arc length, filler rod position, and traverse speed. The operator then observes the process and intervenes only when necessary.
TIG welding can be performed with both AC and DC power supplies, with currents ranging from 15 to 350 amps.
How to perform TIG welding
The operator can then start the gas supply from the gas bottle. The valve on the TIG torch can be used to regulate the gas flow. Hold the torch over the area to be welded without touching it. To create an arc between the tungsten electrode and the workpiece, the operator must press the foot pedal. The filler metal is melted, forming a welding pool on the part. When the weld pool has cooled down and solidified, a weld joint has been created.
For all its advantages and the quality of the weld, TIG is a significantly slower process than stick or MIG welding. Therefore, despite the low speed of the process, it is used where high-quality welds are essential.
TIG welding equipment
In comparison to stick and MIG welding, TIG welding equipment is often more expensive. For less than $1,000 you can buy the Everlast Power TIG.
Torch
There are a variety of torch sizes available with different amperage ratings. The torch body contains electrodes and gas jets.
Water cooling system
High amperage can cause the torch to heat up. The torch is prevented from overheating by a water cooling system. This provides greater efficiency than air cooling.
Suppression of the constant current
Magnesium and aluminum alloys are difficult to weld with TIG. When welding aluminum, an arc occurs between dissimilar metals (tungsten and aluminum), allowing AC to convert to DC. This unwanted conversion is prevented by a DC suppressor.
The tungsten electrode
Tungsten is an ideal material for TIG electrodes as it has a very high melting point of approximately 3000 degrees Celsius. In addition, tungsten is highly electrically and thermally conductive. Zirconium and thorium are added to the tungsten to prolong electrode life and increase arc stability. In addition, it may be necessary to change its polarity.
The gas nozzles
This nozzle is manufactured from a high-temperature ceramic material that can withstand high welding temperatures. Different nozzle shapes are available to suit all welding applications.
Gas Lensing
Turbulent gas flow may not give the best results. Turbulent gas flow can be used to achieve the best results.
In some cases, a gas welding lens can reduce the flow of protective gas. However, gas lenses should not be used exclusively for this purpose.
All other things being equal, such as amperage, torch position, and range of tungsten electrodes, the laminar flow through the gas welding lens provides a more uniform distribution of protective gas in the welding area, and less gas (gas welding flow) can be used than with standard collet holders.
High frequency starting
Most modern gas tungsten arc welding machines have a high-frequency start function. The welding arc can be ignited without the electrode being pressed against the workpiece. Thanks to high-frequency starting, the welding arc can be started even when the electrode is only a few centimeters away from the workpiece.
Since it is very difficult to pull the electrode upwards to create a welding arc with a tungsten electrode, a high-frequency start makes the process much easier.
As soon as the arc is established, the current and voltage return to normal operating settings. Wear on the tungsten electrode is prevented by this automatic control of voltage and current.
Tipps zum WIG-welding
Beginner welders should practice on scrap parts first, as TIG welding requires practicing many moves, such as feeding filler metal, holding the welding torch correctly, and operating the foot switch.
The angle of the light should be about 75 degrees. A distance of ¼” to 1/8″ should be maintained between the electrode and the workpiece being welded.
Now that you have learned about welding, you should take up this interesting and engaging profession. It is a well-paid technical profession for which no university degree is required. And with good prospects, because the demand for welding specialists will continue to grow.
How Do I Start Welding Safely?
Before deciding to start welding, you should provide yourself with everything you need, namely, wearing welding gloves and a welding helmet, a flame-retardant jacket, and safety glasses. If necessary, these mandatory security attributes can be purchased at a specialized welding shop.
For beginners
Every welder should always keep two medium to large metal files in a drawer at all times. A hammer for chipping and a wire brush are also necessary items.
Remember that in the welding world, shock, burns, and arc damage are common, especially for novice welders. Be careful and begin welding only in the presence of an expert. Studying the specifics of each welding career will give you an idea of what type of training and educational program you should take.
After graduating from high school, you will have the opportunity to continue your education by taking a Welding Certificate Program or a college course.
FAQ
- What should a beginner welder know? A beginner welder should know the basics of the different a type of welding, such as arc welding, gas welding, and MIG welding. They should also be familiar with the safety precautions associated with welding and the proper use of protective gear. They should also understand the basics of working with different metals and how to prepare a workpiece before welding.
- How do I know if welding is for me? The best way to find out if welding is right for you is to try it. Talk to people who work in welding, attend welding courses and practice welding to get an idea of the welding job itself and the skills needed.
- Can you weld with no experience? Yes, it is quite possible to weld without any experience. While it is recommended to take a welding course or find an experienced welder to teach you the basics, you can get started by studying online tutorials, and practicing on scrap metal.
