Guides Archives - The Welder Helper

Welding 101 – The Welding Process

The Welder Helper Team — Mon, 24 Feb 2020 07:30:07 +0000

The Welding Process

So you’ve made the decision to add a welder to your home shop or garage but are now facing the decision of what kind of machine to get. Should you get a MIG or TIG machine or one that does both? What’s the difference? It’s time for Welding 101 – The Welding Process!

To answer these questions, we need to understand the type of welding or ‘process’ a diy’r (or pro) would typically use at home.

Each has strengths and weaknesses as well as varying degree’s of difficulty for the beginner. All will require safety equipment as well as what we call ‘consumables’ (welding wire, electrodes, shielding gas) used during the process.

What does it mean to 'Weld'?

What are we actually doing when welding? All the processes are looking to achieve the same result. Fusion. We’re fusing two similar materials using high heat to literally melt them together.

To fully form a welded ‘joint’, filler material is added to the molten puddle (the weld puddle) as well. Upon cooling, the welded joint is typically as strong or stronger than the base materials.

A fillet weld gauge can be used to check that your welds meet your necessary requirements.

Let’s briefly examine each process and go over their benefits and weaknesses.

Stick Welding (Shielded Metal Arc Welding)

Stick welding (SMAW) requires only a welding machine (stick welder), a grounding clamp and a flux covered electrode held by a ‘stinger’. An electric current is used to form an electric arc between the electrode and the materials to be joined. During the process, the core or wire will melt into the weld pool while the flux simultaneously creates a gas shield over the weld. Shielding is critical to protect the weld from oxygen, water vapor and other contaminants.

While the process sounds deceptively simple on paper, having the fewest ‘moving parts’, it can be tricky for the beginner. It’s more alike to learning to drive on the family Suburban rather than your mom’s Honda. There are however several benefits to learning and using the process.

Suitable materials:

Carbon Steel
Stainless Steel
Nickel based alloys
Chrome
Aluminum (Difficult)

Advantages:

No separate shielding gas required
Works well outdoors and in windy conditions
High portability
Minimal joint prep (no need to remove mill scale or rust)

Disadvantages:

More skill and practice required
Products slag and spatter
Slower process

MIG Welding (Gas Metal Arc Welding)

MIG welding or (GMAW), is a process in which an electric arc forms between a wire electrode and the material to be welded. As in other types of welding, a ground clamp is also attached to the work piece in order to complete the circuit. The wire itself is motor feed automatically from a spool through a hose and out a MIG gun as the trigger is depressed. An inert shielding gas (usually Argon, CO2 or a mix of the two) is also simultaneously fed through the hose via a nozzle in the gun to protect the weld. Alternatively, flux-cored wire can be used which removes the need for dedicated shielding gas. It’s a bit more sophisticated and complex than other methods as far as the components and setup.

The complexity on the back end however is what makes this process the easiest to learn as well as the most productive. MIG welding machines are a great way to get started in welding.

You’ll find MIG welding used frequently in metal and pipe fabrication shops due to its speed and production capability. It’s also a favorite of the automotive industry as its well suited for welding thin metals.

Suitable materials:

Carbon Steel
Stainless Steel
Nickel based alloys
Magnesium alloys
Chrome
Aluminum

Advantages:

Easy to learn
Wide range of metals can be welded
More welding positions
Fast process
Less spatter

Disadvantages:

Complicated setup
Low portability
More joint prep (metals and grounding point need to be cleaned)
Not wind friendly
Some additional consumable costs

TIG (Gas Tungsten Arc Welding)

TIG welding or (GTAW) is a process by which an electrical arc is created between a non-consumable tungsten electrode and the work piece. Similarly to MIG welding, an inert gas (usually argon) is also supplied via a nozzle in the torch head called the collet body. A grounding clamp is also attached to the materials to be welded. Filler material in introduced into the weld pool via the operator’s free hand. Many machines also offer amperage control through a foot pedal.

Very difficult to master, TIG welding requires considerably more skill than other processes but also produces the most aesthetically looking welds. Well suited for high precision or small welds, TIG offers precise heat control and can be used on a wide variety of materials. Often used in demanding applications in aerospace, aviation and motorsports.

Suitable materials:

Carbon Steel
Stainless Steel
Nickel based alloys
Magnesium alloys
Cobalt alloys
Copper alloys
Titanium
Aluminum

Advantages:

High quality welds
Wide range of metals can be welded
Good for precise welds
Less smoke and fumes
No spatter

Disadvantages:

High skill demands
More joint prep
Slower process

Conclusion

So which process and type of machine do you choose? While much of that will depend on your intended use, materials, etc, even for occasional welding, every ‘weekend warrior’ and pro alike needs a good MIG machine. With its flexibility and ease of use, it’s also the best process for the ‘single’ welder garage or workshop.

And with budget models starting at $150.00, there really is a MIG machine out there for everyone.

For those who want the best of both worlds (or can’t justify a dedicated TIG welder), many of the new machines on the market have some multi-process capability as well.

And what about a stick welder? Well if you need portability or a backup machine, having one around certainly won’t hurt. Just remember to practice!

The post Welding 101 – The Welding Process appeared first on The Welder Helper.

A Beginners Guide to Welding Your First Joint

The Welder Helper Team — Mon, 24 Feb 2020 07:29:53 +0000

Why Weld?

Welding can be a great skill or hobby, and it can even evolve into a part-time job or a full-time career. Learning how to weld isn’t as difficult as you think. It’s certainly something you can pick up and use for DIY projects without spending a lot of time or money on classes. Welding is like any other skill though, in that it does take some practice. Before actually picking up a MIG gun or electrode, check out our Beginners Guide to Welding your first Joint for a general overview and important tips.

Step 1: Welding Safety

Safety needs to be your number one concern when it comes to welding. While some aspects of welding can be dangerous, once you learn basic safety precautions it can be a great new skill to learn or add to your resume. You can easily burn yourself or damage your vision without the right safety equipment. It’s also possible to start a fire while welding, so you need to make certain your work area is safe, too.

Your basic safety equipment should include welding gloves, a helmet, a jacket or welding apron, safety glasses, work boots, and optionally a respirator. You want to make certain the helmet you’re using is dark enough that it protects your eyes from the incredibly bright light of the welder. Many experts recommend purchasing an auto-darkening helmet. The glass in these helmets incorporates LCD technology that can almost instantaneously darken the glass to protect your eyes when bright light is detected. When there’s no overly bright light, the glass is clear.

You do want to make certain that all of the equipment you purchase is rated for use in welding. For example, while there are many thick work gloves out there, not all of them are going to fully protect you given the temperatures seen in welding.

You’ll also want to have basic safety equipment around your worksite. This equipment includes a fire extinguisher, fire blankets, and an eye wash bottle or station.

Step 2: Choosing a Process

If you haven’t welded before and don’t know much about it, you may assume that all welding is the same. While there are several methods of welding used today, we’re going to focus on the three most common. You’ll want to pick one to start with, but you can certainly try all three to see if there’s one that you like better or that works better for a specific project.

Stick welding or Shielded Metal Arc Welding (SMAW) is the most popular arc welding method. This method uses a power source and an electrode (the “stick” of stick welding) of fixed length to join different metals. Electric current flows through the electrode and arcs across to the metal you’re joining. The electrodes are covered in a flux which when ignited, creates a shield of gas around the arc and weld puddle. Filler metal also comes from the electrode. This type of welding has several uses and requires the least joint preparation.

Metal Inert Gas or MIG welding makes use of an automated wire-feed welding gun instead of a stick electrode. In addition, shielding gas (usually an Argon mix) is pushed out of the nozzle and onto the two materials being welded together. The gas protects the wire from air impurities, creating a cleaner weld. MIG welding is generally considered the easiest method for the beginner.

Tungsten Inert Gas or TIG welding makes use of a tungsten electrode to create an arc along with shielding gas feed by the TIG gun. Filler material is introduced via a filler rod in the operators other hand. TIG will produce the most aesthetic welds but at the cost of some speed compared to the other methods. It also requires a bit more skill.

Step 3: Equipment

In addition to your safety gear, you’ll need a number of other pieces of equipment. The most important and expensive item will be your welder. Many welders out there allow you to perform all three types of weld (a multi-process machine), so you don’t necessarily need to be concerned with limiting yourself to one method right away. Experts recommend investing in a good welder rather than buying a cheap one—you do get what you pay for.

Other basic items you’ll need to get started include:

Extra Consumables (Welding Rod or Wire, Nozzles and Tips)
Shielding Gas (MIG/TIG)
A Wire Brush and Chipping Hammer
Welding Pliers
An Angle Grinder
C-Clamps

Down the road, investing in a welding cart certainly helps in even small moves as well as keeping everything organized. A good welding table is also invaluable and makes a great first project.

Step 4: Preparation

Good welding joints need preparation. Removing mill scale, dirt and other impurities can be the difference between a marginal weld and one that will last forever. Don’t be shy with the angle grinder. Exposing clean bare metal also gives us a nice strong arc to work with. Grinding a clean spot for your ground clamp is also recommended for a solid welding circuit.

Once your materials are prepared, we can now setup our welding machine and shielding gas and ‘plan’ the joint. The last thing we want is to find out you can’t reach a location mid-weld.

Using clamps to secure the materials while tacking is a good idea especially if you’re welding heavy components.

Step 5: Welding the Joint

Now it’s time to finally weld the joint. There are a few different steps to actually welding two pieces of metal together. First, you need to determine the type of joint you’re going to use.

Common Joints

Butt – The metals are welded side by side with the filler material in between them.
Lap – The two pieces overlap.
Edge – The two pieces are joined on one edge that is completely covered with filler material (imagine the materials like pages in a book and the edge joint as the spine).
T Weld – One piece is welded perpendicular to the other, creating a T shape. The weld is done on both sides of the perpendicular piece.

Hand Position

Next, think of your hand position. You want to move as few parts of your body and the welding gun as possible so that everything is steady and flows smoothly. You want to use both hands on the welding gun or use your off-hand’s wrist to guide your other hand. Do a few practice runs with the welder turned off before beginning to weld. When welding depending on the process used, we’ll either be pushing or pulling the gun/electrode. Both have pros and cons to them, so it’s best to practice both.

Tack Welding

Start off by tack welding your materials. We aren’t looking to deposit a ton of material here but rather just enough to hold everything together. Tacking lets us preset pieces to be welded and gives us a chance to make changes before welding. It’s also the time to check for level or make sure things are square.

Laying Down a Weld Bead

We now lay down our first ‘bead’. Beads are to welding what seams are to sewing—they all get the job done, but they do have different uses. Stringer beads are the most basic type of bead. You either push or pull your gun across your joint with very little side-to-side motion. The other common option is to use a weave bead. Weave beads are good for wide welds. Here, you weave back and forth along the joint often times performing a pattern such as a cursive letter ‘e’.

It’s important to move at a steady consistent pace when welding. We don’t want to linger in one spot too long or rush the joint. Depending on the thickness of your materials, the joint may require more than one bead or ‘pass’ as well. Brushing or grinding between passes may be required for certain welding processes too.

Once you’ve finished your final bead, we are ready for the final step.

Step 6: Final Grinding + Finishing

The final step is to grind the weld down. This may not always be necessary—if the look of the weld doesn’t matter or if the weld won’t be visible, it’s fine to leave it as it is. If you do want to grind, though, you’ll want to carefully grind along the weld. Don’t grind across it as you’ll weaken its integrity. Take it slow, and be very careful that you don’t over-grind right through the weld.

Welded joints will rust (they are often the first area to rust too) so some protection may be required if the joint will be exposed to a wet or damp environment. A rust-through primer can help but can be pricy if you need a lot of it.

Final Thoughts

Now that you’ve got an idea of the basics of welding, you’re ready to give it a try! Welding is something that you can teach yourself with the right resources and some practice. In the end, you may find that you’ve picked up a new hobby that you really enjoy and a new skill that has many practical applications.

The post A Beginners Guide to Welding Your First Joint appeared first on The Welder Helper.

MIG vs TIG – Which to Choose for your Next Project

The Welder Helper Team — Sat, 29 Dec 2018 08:44:38 +0000

MIG vs TIG

Just buy a welding machine and want to test it out? There are a number of different welding methods you can use, but the two most common processes for home projects are MIG and TIG welding. So which method do you choose for your next project?

While they may sound similar, each is distinct and often one or the other is better suited for a particular weld. The advent of low cost multi-process welding machines (welders that can do more than one process), brings the decision to the forefront for every weekend welding warrior.

Let’s take a look at what MIG and TIG welding are and how they differ from each other.

What Is MIG Welding?

A MIG (Metal Inert Gas) welder works by continually feeding a special metallic wire into your weld through the nozzle of a MIG gun. This wire acts as filler material during the fusion of the two materials being welded together. An inert gas is also supplied via the nozzle to protect the weld during the process. This gas is usually argon or a mixture of argon and CO2.

The arc created is fairly large and is typically hotter than the arc created by TIG welding and by other forms of welding. It’s also wider, which means it can’t penetrate as far as a narrower arc can.

MIG welding actually benefits from a mixed or combination shielding gas compared to a fully 100% inert gas. Pure inert gasses can reduce effectiveness of the arc, making the entire welding process more difficult and producing more spatter.

What Is TIG Welding?

With TIG (Tungsten Inert Gas) welding, a tungsten electrode is used to create an arc and fuse the metal you’re welding. An inert gas flows through the torch and over the arc in a way that’s similar to MIG welding. TIG works best with pure argon as the shielding gas.

As the metals to be joined liquify, a filler rod material is fed into the weld puddle to form the joint and bond the two pieces together. Rod is available in various diameters and materials to suit the base metals being welded. TIG welding usually requires both hands, one of which holds the torch while the other holds the filler material. Some types of joints can also be done without filler (Autogenous Welding).

Overall, TIG welding arcs are narrower than MIG arcs, so the heat is focused on a smaller space. This allows for TIG welding to penetrate farther, though it’s slower to weld. Welders are available in either dedicated process (TIG only) or multi-process.

Pros and Cons of MIG Welding

PROS

Being a semi-automated process, it tends to be faster. Production rates or ‘weld inches’ will be considerably higher compared to TIG.
Easier to Learn. For the beginner, the MIG process tends to be easier to pick up and easier to master.
More welding ‘positions’ available. MIG welding also has a slight advantage with difficult to reach joints. While two hands are still recommended to steady and guide the MIG gun, single handed welds are certainly possible.

CONS

Compared to TIG welding, there is a bit more ‘care and feeding’ required with a MIG machine. The spooling mechanism should be lubricated and cleaned per the manufacturer’s suggestions. Tips and nozzles also need to be liberally replaced to maintain a high quality arc.
Slightly higher consumable cost. Both processes require shielding gas and filler materials but the need for additional MIG tips and nozzles required during welding give TIG a slight advantage here. Of course, accidentally dipping TIG electrodes into your weld puddle can make the costs about equal.
More fumes and spatter. All welding produces smoke and fumes and depending on the type of wire used, MIG will produce slightly more.

Pros and Cons of TIG Welding

PROS

Precise, high quality welds. With a narrower arc and less spatter, TIG welding is capable of producing absolutely beautiful welds.
Wide range of materials can be welded. While MIG welding can be used on several types of materials, metals such as cobalt and copper alloys or titanium are outside its scope.
Great for thin materials. TIG’s precise heat control is fantastic for welding thin-walled materials commonly found in the automotive and Motorsports fields.

CONS

Slow process. This isn’t the welding method for quick + dirty joints. Stay with MIG (or even Stick welding) for that. Additional dexterity required here as well since most of the time, both hands are required.
More skill required compared to MIG welding. There’s more variables at play when TIG welding that the welder needs to focus on over and above feeding filler rod. More hours practicing compared to MIG welding are needed to achieve the same level of proficiency.
More joint preparation and cleaning. While both processes require prep, a good TIG joint requires that your surfaces are immaculate.

MIG or TIG - So which do you choose?

Unfortunately the answer to this question is going to be ‘It depends’. As a guide, it usually boils down to:

What materials am I welding (type of metal and thickness)
Are my joints going to be visible (do I care how they look)
What’s my skill level

The size of your project also plays an important factor. MIG welding is usually the best option for large projects. Welding 100 inches on a MIG machine will definitely be faster than doing it using a TIG setup. Likewise, heavier or thicker materials are best left to MIG welding as well.

New welders may want to start out with MIG welding simply because it’s easier to learn and certainly more forgiving than TIG welding. Much of practical experience learned doing MIG can be transferred over to TIG welding too.

When the time comes for precision and nice looking joints however, TIG is the way to go. Many if not all the exposed welds we see in daily life were done via TIG. The practice required to really get good at TIG welding is well worth end results.

Our advice when choosing for your next project? Learn both methods and use the one best suited to your project. Chances are pretty good that a new welder bought today will be a multi-process model, so why not have the skills to use it.

The post MIG vs TIG – Which to Choose for your Next Project appeared first on The Welder Helper.

The Welding Checklist: Start Here!

The Welder Helper Team — Sat, 29 Dec 2018 08:43:43 +0000

What exactly do I need? - A Checklist

Just getting started and need to gear up? Start here with our Welding Checklist before laying your first bead. Knowing what you to buy can be a little daunting especially for the beginner.

The military and NASA love checklists and so do we. We’ve compiled a listing of items to answer that along with recommendations from the pros.

Personal Safety

Don’t even consider turning on your welder before having your safety equipment in place. Taking a few precautions now will ensure that you’re welding this weekend
and not driving to the emergency room.

Welding Helmet – Whether you get the latest Auto-Darkening model or prefer an old school version, a good helmet is critical. In fact mandatory. Remember to keep it clean too. You can’t weld what you can’t see.
Welding Glooves – High heat, sparks, welding arcs, sharp edges. Enough said. Protect your hands.
Welding Apron/Jacket or Sleeves – Unless you’re going for the ultimate farmer’s tan, you need to protect any exposed skin. Same reasons for gloves apply here too. Get yourself a good welding jacket.
Safety Glasses / Shield – There’s dozens of ways for an object to get launched back at you when grinding, chipping or cutting. Protect your eyes.
Ear Plugs – Optional but recommended. A typical angle grinder will exceed 95dB or more depending on the material, type of wheel, etc.
Respirator – Recommended. The noxious witch’s brew of smoke and chemicals released in most welding processes isn’t pretty. Good ventilation is a must as well.
Work Boots – Most things you’ll be working with have some decent weight to them. Get some good steel toed boots before your next gravity demonstration.

Site Safety

The ‘site’ in site safety applies to your garage, shed or full blown welding shop. A clean site is safer than a dirty one. Invest in a shop vacuum or at least a good broom. The slag, scrap or metal filings produced while welding will accumulate over time and create a hazard should you or someone else take a spill.

Keep your site free of clutter. There’s probably going to be a few fantastic ignition sources in your hands and having a working environment full of flammable items isn’t a good idea. Also watch out for sources of vapors (stored gasoline, paint thinner, etc).

Fire Extinguisher – Put out the small fires before they become the big fires.

Fire Blankets – Lots of protection uses for these. Pick one up.

Eye Wash Bottle / Station – Every weekend welder or shop should have an eye wash station. Hang it someplace obvious and easy to reach.

Welding Curtains – Optional but recommended. You never know when someone might come into the vicinity of the welding arc.

Welding Equipment

Finally, we get to the actual business of welding. First item is obviously a good welding machine.

Welder – Stick, MIG, TIG or Multi-Process. This is where the magic happens. Read your manuals, watch a video, learn your machine.

Tools

MIG Welding Pliers – Indispensable for all processes.

Chipping Hammer – You’re going to need one of these. Newer designs come with shock reducing handles and in your favorite weight.

Wire Brush – Another must have for every welder.

Soapstone + Holder – Essential for marking steel or aluminum.

Clamps – You’ll need to hold things together before tacking. Get a few in various sizes or a kit.

Table / Bench – Before you have the skills to make your own, you may want to invest in a nice steel table or bench.

Consumables

Spare Contact Tips (MIG) – Have some replacement tips on hand. Cheap and you’re gonna need them.

Nozzle Gel (MIG) – While on contact tips, why not protect them a bit in the first place.

Welding Rod (Stick) – Never hurts to have a few pounds of the basics on hand (6010/11, 7018) if stick welding is your thing. Make sure to get a storage container too to keep out humidity and moisture.

Welding Wire (MIG) – Better deals on the 10-pound spools but nothing wrong with the 2-pound ones for occasional use.

Tungsten Electrodes (TIG) – You will need a few spare electrodes, especially when first learning. A dedicated sharpener is nice but pricey.

Shielding Gas (MIG/TIG) – Mandatory and available even from online sources.

Specialties

Tig Finger Heat Shield – Some swear by these little protectors
Mag-Mate Magnetic Torch Holder – Super handy for any kind of welding

Accessories

Welding Cart – Welding machines are getting lighter. Gas cylinders aren’t. Make your setup mobile with a quality welding cart.

Welding Pliers – Indispensable for all processes.

Angle Grinder – These go hand in hand with welding. Get plenty of extra wheels too.

Chipping Hammer – You’re going to need one of these. Newer designs come with shock reducing handles and in your favorite weight.

Wire Brush – Another must have for every welder.

Scribe / PaintStick – Whichever you prefer. Scribes are more accurate.

Clamps – You’ll need to hold things together before tacking. Get a few in various sizes or a kit.

Table / Bench – Before you have the skills to make your own, you may want to invest in a nice steel table or bench.

Electric Hoist – Optional but recommended. You just finished your new welding table and it weighs 250lbs. Ouch. Save your back with a good electric hoist.

Final Thoughts

There you have it. Our picks for every aspiring welder or hobbyist. We hope this time saving list helps on your next project. Keep welding and keep practicing!

The post The Welding Checklist: Start Here! appeared first on The Welder Helper.