About Welder and Welding - Basic Information

A welder is an electrical tool that uses high-frequency currents to fuse metal. In other words, a welder melts the metal together. They are mainly used in industrial settings and not commonly found at home.

A welder can be used to work on almost anything that’s weldable, such as copper piping, steel beams and pipe, aluminum welding wire or gas pipe fittings.

A welder operates by producing a large amount of electromagnetic energy, which passes through the metal to be welded, melting it and connecting the two pieces of metal together.

This type of welding is also known as shielded metal arc welding or metal inert gas welding (MIG welding). It’s the most common type of welding used today because it can be used safely on any metal surface. The electrode material is usually made up of tungsten, molybdenum or a combination of both.

Safety issues

Welding is by no means a safe activity. It involves the use of hot metal and intense levels of ultraviolet radiation.

These levels of radiation are dangerous, so you should always wear protective gear. A welder produces ultraviolet rays that can cause serious eye problems, so make sure to use safety glasses with side shields when operating one. Protect your skin from this heat as well by wearing long sleeve shirts and long pants to prevent burns and cuts.

A welder is an electrical tool that uses high-frequency currents to fuse metal. In other words, a welder melts the metal together. They are mainly used in industrial settings and not commonly found at home.

A welder can be used to work on almost anything that’s weldable, such as copper piping, steel beams and pipe, aluminum welding wire or gas pipe fittings.

What is Welding?

"Welding" is simply the joining of metals by using heat or chemical energy. Welding is basically accomplished by melting the materials to be joined and forcing them together while they are hot. When they cool, they become fused into one solid piece of metal. The process of actually melting the material is called "reducing" or "fusing."

Welding Processes

There are several different welding processes that an average person can perform. Many of these welding processes can be modified to produce different results, depending on the type of machine used.

Gas welding

Gas welding is a process involving the use of a gas flame as the source of heat. It is similar in some ways to the electric arc welding process. Gas welding is used for joining nonferrous metals, such as brass and copper, and many types of alloy steels.

Arc welding

Arc welding is a process involving the use of an electric arc at high voltage to heat metal. It's often used to join steel, aluminum and most non-ferrous metals, such as copper and brass.

In arc welding the molten metal is forced through a hole in one piece of metal and then into another piece. The metal goes from liquid to semi-solid, solidifies, is cooled rapidly and forms a permanent seam. The process is also known as "pickling" or "shot peening.

Arc welding processes

The arc welding process involves the use of high-frequency power, and arc-controlled electrode voltage that creates an electric arc in the molten metal. The electrical energy is controlled by an electrical circuit. The electric arc is produced by the interaction of a high-voltage electric current with a small piece of metal known as an arc conductor, or the "arc tip."

The power supplied to the weld area can be from AC or DC voltage sources, depending on the type of equipment used.

The process of making a weld can be summarized as follows:

  1. The work is cleaned and prepared for welding.
  2. A fusion and joining tool is used to cut the joint at the proper location on both materials.
  3. The voltage source of the welder is adjusted to deliver the correct amount of current (voltage).
  4. The electrode and work are positioned so that the metal is melted by the electrical arc.
  5. The metal is melted completely (fusion).
  6. The molten metal is forced into the joint at great speed, spreading out along its length to form a single mass of metal (solidification).
  7. The molten metal cools quickly as it leaves the contact area, forming a solid mass of metal (crystallization).
  8. The weldment is inspected to ensure that it has been completed properly.
  9. The weldment is checked for defects, and any necessary corrections are made.

Arc welding power supplies

There are two types of arc welding power equipment: DC and AC. Both types consist of a power supply that delivers direct current or alternating current (AC) to the machine, and the actual welder that contains the electrodes and controls to manipulate the high-voltage circuit.

A DC system is made up of three basic elements: a transformer, rectifier and inverter. The transformer is similar to a step-up transformer, which boosts voltage.

An AC system consists of two high-voltage transformers, one rectifier and an inverter. The secondary of the inverter provides the DC voltage for welding processes, and the primary provides the AC for welding processes.

The equipment used to perform arc welding is called a welder. There are several different types of welders available on the market, but numerous safety issues must be addressed with any type of welder.

Welding Techniques

There are many different welding techniques that can be used to join metals. The technique used depends on the type of metal being welded, the properties of the metal, and the work piece being welded.

This is not a complete list. For example: When welding mild steel, the arc needs to be longer to produce a weld that is stronger. This method is called "long arc." The arc must be shorter when welding aluminum. The arc must be longer when welding cast iron, to prevent breaking the piece.

Choosing the right welder(s)

The type of material used for building a welder can vary greatly. Welders are usually made out of metal which is resistant to heat and electricity. Most welders are made out of some sort of steel alloy, but that could vary depending on the specifications desired by the manufacturer.

Resistance welding

Resistance welding is a process that produces fusion by heating the material to be welded in a direction at right angles to the welding surface. It is also known as spot welding or flash welding. In general, resistance welding processes are used for joining materials that have similar melting points and for producing a joint with a narrow heat-affected zone. They are primarily used in industrial settings and not commonly found at home.

In resistance welding, the electrode is usually a soft metal core, such as copper or magnesium. The welding element is then welded to the base material, joined and melted by the electric current. The molten metal flows toward the weld joint using heat transfer through conduction and convection.

Energy beam welding

In energy beam welding, a stream of either electrons or ions is used to produce high temperatures and molten metal. Energy beam welding may be used to join different types of materials, including metals and ceramics. Electron-beam welding is often used to join dissimilar metals. The electron stream reacts with the material being welded and produces heat. When the heat melts the material, it is forced into a joint between two pieces of metal. The fusion of the metals helps bind them together.

Ion-beam welding is used to join similar metals and needs a higher beam density. Ions are produced from a source of current, and when these ions hit metal atoms, they cause the atoms to become hot. The heat is then transferred to the metal being welded, resulting in fusion.

When using an energy beam welding method, the size of the welder determines which types of materials may be joined. Because of the high energy beam, large welder to join intricate structures cannot be used.

Solid-state welding

Solid-state welding is an advanced process that joins materials that have different melting points, such as aluminum and steel. In this method, a metal pellet positioned between the electrodes is used to create an electrical arc when current is applied. During the arc, heat is transferred from one piece of metal to another through conduction and convection.

The properties of solid-state welding are its versatility and versatility in terms of parts joining. Solid-state welding can join dissimilar materials, even if their melting points are different. It can also be used to join different materials together, including metals and ceramics.