Difference between revisions of "Category:Welding Shop"

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* Oxy-Acetylene Torch
 
* Oxy-Acetylene Torch
 
* Lincoln Wire Welder
 
* Lincoln Wire Welder
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*[[Plasma Cutter]]
  
 
== Consumables ==
 
== Consumables ==

Revision as of 13:33, 10 February 2013

The welding station

Contents

Safety First

Welding is a great way to join and form metal. Welding use comes at some risk. Let's be careful out there.

  • Eye protection. You must protect your eyes from the bright welding light. If you are TIG, MIG or Arc welding you should be wearing a welding helmet. If you are using oxygen/acetylene welding then you should be wearing a pair of gas welding goggles or the dark face shield.
  • Consider the eye protection of others around you. Will they get flashed by your welding arc? Use the welding safety screens to protect others in the shop.
  • Proper clothing. Shorts and T-shirt won't do. Arc welding gives off extremely bright UV light, and you will become badly sunburned in no time. Best is long sleeve cotton clothing and long cotton pants (tight knit lightweight wool is actually the "best", but hard to find). Polyester clothing will melt easily and should never be worn by anyone welding.
  • Proper footwear. Leather closed toe shoes should be worn. It doesn't take long for a small hot bead of metal to burn right through the top of your canvas tennis shoes. Also consider wearing boots instead of low cut shoes. Think what will happen if a drop of molten metal gets inside your shoe. Ouch.
  • Wear welding gloves to protect your hands. Mechanics' gloves tend to have plastic or rubber which will melt while welding.
  • Don't forget that it takes time for hot welded metal to cool. Use pliers to lift work off of the table. Don't leave hot work where an innocent bystander could become burned. If you aren't sure about the temperature of a piece, assume it's hot until proven otherwise.
  • Quick.. where is the nearest fire extinguisher?


Equipment

Consumables

Let's Learn to TIG Weld!

References:


Machine settings: What material are you welding?

  • Steel? If you are using steel, set the Polarity Selector Switch (large three position switch on the right hand lower area) to the full clockwise position, Direct Current Straight Polarity (DC Electrode Negative). You should be using the red tungstens (2% Thoriated) for DC TIG welding. The "High Frequency" selector can be on "Start" or "Continuous", but "Continuous" will mess up nearby radios and wear out the machine faster.
  • Aluminum? If you are using aluminum, set the Polarity Selector Switch to the full counterclockwise position, Alternating Current (AC). You should be using the green tungstens (pure tungsten).for AC TIG welding. Switch the "High Frequency" selector to "Continuous".

Choose machine settings and tungsten based on the following chart:

Material Being Welded

Material Being Welded Thickness

Tungsten Type

Tungsten Electrode Diameter

Cup Opening (ID)

Filler Metal Diameter

Polarity

Amperage Range (Amps)

P&H Range Selector Switch

Argon Flow Rate

Welding Speed

Notes:

Steel

1/16"

Red (2% Thoriated)

1/16"

1/4 to 3/8

1/16"

Straight Polarity (DCEN)

50-80

Medium

22 to 162 Amps

11 cfh

12 inches / minute

 

Steel

3/32"

Red (2% Thoriated)

1/16"

1/4 to 3/8

1/16"

Straight Polarity (DCEN)

80-110

Medium

22 to 162 Amps

11 cfh

12 inches / minute

 

Steel

1/8"

Red (2% Thoriated)

1/16"

1/4 to 3/8

3/32"

Straight Polarity (DCEN)

85-120

Medium

22 to 162 Amps

11 cfh

12 inches / minute

 

Steel

3/16"

Red (2% Thoriated)

3/32"

1/4 to 3/8

1/8"

Straight Polarity (DCEN)

125-200

High

78 to 342 Amps

13 cfh

10 inches / minute

 

Steel

1/4"

Red (2% Thoriated)

1/8"

1/2

3/16"

Straight Polarity (DCEN)

225-300

High

78 to 342 Amps

13 cfh

5 inches / minute

Oops.  Too hot for air cooled torch. Requires water cooled torch.

Aluminum

1/16"

Green (pure tungsten)

1/16"

1/4 to 3/8

1/16"

Alternating Current (A/C)

65-75

Low

10 to 72 Amps

15 cfh

12 inches / minute

 

Aluminum

1/8"

Green (pure tungsten)

3/32"

3/8 to 7/16

3/32" or 1/8"

Alternating Current (A/C)

115-135

Medium

35 to 205 Amps

17 cfh

12 inches / minute

 

Aluminum

3/16"

Green (pure tungsten)

3/32"

7/16 to 1/2

3/32"

Alternating Current (A/C)

125-150

Medium

35 to 205 Amps

21 cfh

11 inches / minute

 

Aluminum

1/4"

Green (pure tungsten)

3/32"

1/2 to 3/4

3/32"

Alternating Current (A/C)

190-220

High

112 to 420 Amps

25 cfh

10 inches / minute (If using 1/8 filler rod, use 2 passes)

 

Aluminum

3/8"

Green (pure tungsten)

1/8"

5/8

1/8"

Alternating Current (A/C)

110-260

High

112 to 420 Amps

29 cfh

Requires 2 passes, 1st pass 3/32 filler@220-260 amps, cover 1/8" filler at 110-130 amps

Oops.  Too hot for air cooled torch. Requires water cooled torch.

Aluminum

1/2"

Green (pure tungsten)

1/8 or 5/32"

5/8

1/8"

Alternating Current (A/C)

120-290

High

112 to 420 Amps

31 cfh

Requires 5 passes, 1st pass 3/32 filler@270-290 amps, remainig passes 1/8" filler…

Oops.  Too hot for air cooled torch. Requires water cooled torch.



Pages in category "Welding Shop"

The following 4 pages are in this category, out of 4 total.