THE IMPORTANCE OF WELDING MACHINES
Welding is the process of joining two materials like steel, aluminum, brass, stainless steel, plastic or
polymer and fusing them. Welder is the equipment used in welding. Molten metal or plastic called filler, is
used to hold the pieces that are worked on, together. Different kinds of energy sources can be used for
welding materials like, gas flame, an electric arc, a laser, an electron beam, friction or ultra sound. There
are different processes of welding like arc welding, MIG welding and TIG welding.
SMAW or Shield Metal Arc Welding is also known as MMA or Manual Metal Arc or stick welding. This is
used for welding steel;, stainless steel and cast iron. In this type of welding, a consumable electrode
coated in flux is used to lay the weld. Electric current is provided by the welding power supply. This helps
top make an electric arc between the electrode and the metals that are joined. The flux coating
disintegrates and this results in a shielding gas which gives a layer of slag. The weld area is protected
from any impurity by the slag and the shielding gas. The equipment needed for this type of welding are:
continuous power supply, an electrode, an electrode holder and a work clamp.
MIG welding means Metal Inert Gas welding. This is also called Gas Metal Arc Welding or GMAW. This
is used for joining aluminum with other non-ferrous metals. It is used to join many types of alloys and
metals. There is very little splatter in this type of welding. This method is quicker that other traditional
methods like the stick welding method. A continuous, consumable wire electrode and shielding gas are
fed with a welding gun. A constant power source is required for welding steel or aluminum. This type of
welding is mainly used in the sheet metal industry and is thus heavily used in the automobile industry.
The equipments required are: a welding gun, a wire feed unit, a shielding gas supply and an electrode
wire.
TIG welding means Tungsten Inert Gas welding. Reactive metals like magnesium and aluminum can
be joined together with this process. Welding is done manually. With this method, different kinds of joints
like the lap joint, the butt joint, the corner joint and the t-joint can be welded. When TIG welding process is
used, oxidation is prevented. It needs a non consumable tungsten electrode and an individual filler
material. An arc is made between the pointed tungsten electrode and the area that has to be welded.
Since gas shield is used, the welding that is formed is very clean and neat. For shielding an inert gas is
used. Thin metals can be joined well with this type of welding. It is used for welding aluminum,
magnesium alloys, steel, stainless steel, copper, brass and titanium.
FCAW or Flux Cored Gas Welding Gasless needs wire fed welding machines. In this process the metal
is heated, melted and then joined together. The joining is done by continuously fed, consumable tubular
electrode wire. Constant electric power supply is required for this method. In this high speed welding can
be done and it is also portable. So, it is best used in the construction industry. It is generally used in steel,
stainless steel and rusty metals.
Arc welding needs inexpensive equipment and requires electric current. Resistance welding needs
costly equipment and requires the use of additional sheets of metals to encase the material that has to be
welded. A modern technique is laser beam welding or energy beam welding. This is very expensive
but is also fast and accurate. Welding is becoming automated these days. The use of welding robots is
done in the automobile industry.
The right type of welding machine has to be used to fuse two types of materials together otherwise the
result will not be what is required. You should know for what purpose it is going to be used. Then you
should choose the type of welding machine, the power supply needed, whether it is portable, what other
tools and accessories might be needed with the welding machine. The accessories that might be needed
are: the torch, the welding helmet, the welding gauntlet, goggles and the welding curtain.
Thus, the welding machines are definitely important and need to be bought and used with great care.
Welding is a fabrication or sculptural process that joins materials, usually metals or thermoplastics,
by using high heat to melt the parts together and allowing them to cool causing fusion. Welding is
distinct from lower temperature metal-joining techniques such as brazing and soldering, which do
not melt the base metal.
In addition to melting the base metal, a filler material is typically added to the joint to form a pool of
molten material (the weld pool) that cools to form a joint that, based on weld configuration (butt, full
penetration, fillet, etc.), can be stronger than the base material (parent metal). Pressure may also be
used in conjunction with heat, or by itself, to produce a weld. Welding also requires a form of shield
to protect the filler metals or melted metals from being contaminated or oxidized.
Many different energy sources can be used for welding, including a gas flame (chemical), an electric
arc (electrical), a laser, an electron beam, friction, and ultrasound. While often an industrial process,
welding may be performed in many different environments, including in open air, under water, and
in outer space. Welding is a hazardous undertaking and precautions are required to
avoid burns, electric shock, vision damage, inhalation of poisonous gases and fumes, and exposure
to intense ultraviolet radiation.
Until the end of the 19th century, the only welding process was forge welding, which blacksmiths had
used for millennia to join iron and steel by heating and hammering. Arc welding and oxy-fuel
welding were among the first processes to develop late in the century, and electric resistance
welding followed soon after. Welding technology advanced quickly during the early 20th century as
the world wars drove the demand for reliable and inexpensive joining methods. Following the wars,
several modern welding techniques were developed, including manual methods like shielded metal
arc welding, now one of the most popular welding methods, as well as semi-automatic and
automatic processes such as gas metal arc welding, submerged arc welding, flux-cored arc
welding and electroslag welding. Developments continued with the invention of laser beam
welding, electron beam welding, magnetic pulse welding, and friction stir welding in the latter half of
the century. Today, the science continues to advance. Robot welding is commonplace in industrial
settings, and researchers continue to develop new welding methods and gain greater understanding
of weld quality.
Welding Equipment - Basic Equipment,
Protective Gear
Welding Equipment - Basic Equipment, Protective Gear
Getting started with welding can be quite intimidating for anyone who is new to the field. For
experienced welders, there is always another tool to buy for each new project that comes along. The
selection can be staggering with so many choices out there. Baker's Gas and Welding offers top of
the line products from leading companies so that welders don't have to wonder about the quality of
their purchases.
For welders who are either just starting out or looking to add a new tool to their shops, here is a
guide about some basic welding equipment and protective gear.
A Guide to Selecting Welding Equipment
Welders
The voltage power, AC/DC settings, and duty cycle are some of the most important factors to
consider when choosing a welder. The welder will need both the power and a sufficient operating
time (the duty cycle) in order to complete every project. Choosing between stick, MIG, and TIG
welders is a matter of balancing cost, skill, portability, convenience, and the nature of the project.
MIG welding is simple to use, but it is costly and not as portable as the simple stick welding process.
TIG welding creates high quality, clean welds, but it is much more difficult to learn.
Read Baker's Guide to Choosing a Welder
Electrodes
There are specific electrodes that match each of the three main welding processes. Stick welding
uses a consumable electrode that is melted in order to create the weld joint. The E6010 electrode is
one of the most popular electrodes, though the E6011, E6013, and E7018 are frequently listed by
welders as excellent choices.
MIG welding uses a consumable electrode wire that is fed through the welding torch. Most projects
use wire in the following range of thickness: .023, .030, .035, and .045, though a thicker wire may be
needed for larger projects.
TIG welders use non-consumable electrodes that come in five main varieties. Ceriated and
lanthanated electrodes are both good choices for most TIG welding applications. Avoid thoriated
electrodes since they emit radiation when used and require a respirator.
Read Baker's Guide to Choosing the Best Electrode
Clamps
Clamps are a small part of the welding process, but they are critically important for keeping a weld
joint lined up properly. If a workpiece shifts, the weld could be crooked and result in the loss of
significant time if it has to be ground down and welded again.
The more clamps, the better. Some welders have stopped in the middle of their projects in order to
buy more clamps, which shows just how important clamps are for welding.
Find Clamps for Your Project
Angle Grinders
Angle grinders are critical for preparing metal prior to welding, especially for MIG and TIG welding.
An angle grinder is a portable tool that has the arbor at 90 degrees in relation to the tool. Depending
on their size, grinders vary from 500 to 2500 watts. Pick an angle grinder with enough power to
clean the metal sufficiently prior to welding. Every welding project is different, so choosing a grinder
with more power and durability can make a significant difference when planning for future projects.
Explore Angle Grinders
A Guide to Welding Safety Gear
Helmets
Welding emits ultraviolet light rays that are generated by the electric arc. The extreme brightness
generated by welding can cause inflammation of the cornea and burn the retinas of your eyes. Some
people even go blind because they do not use the right welding equipment. Dark face plates are
good for preventing exposure to the ultraviolet rays.
Welding helmets are a critical piece of equipment because they protect your face from sparks and
your eyes from harmful rays. The best choice for a welding helmet is an auto-darkening helmet that
allows welders to keep both hands on task without having to reach up to put on the darkening visor.
A good weld can go bad if a torch shifts even an inch. Therefore experienced welders recommend
the auto-darkening helmets since they can position their torch right where it belongs and start
working immediately. The time it takes to darken a helmet is plenty of time to shift the position of a
weld torch.
Explore Helmets
Gloves
The best welding gloves are made from top-grain leather, which is the high-quality outer layer of an
animal's hide. Welding gloves balance flexibility with heat protection and will vary depending on the
welding process used. Stick welding creates the highest heat and requires stiff, heavy-duty gloves
that can withstand high temperatures, while TIG welding produces the least amount of heat and can
use a lighter and flexible glove.
Goatskin leather gloves are quite popular and are typically ideal for TIG and MIG welding. Deerskin
gloves offer the advantage of shaping themselves to a welder's hand over time and make for an
extremely comfortable fit. The best glove options for stick welding include top-grain pigskin, elk skin,
and cowhide.
Explore Welding Gloves
Grounding Clamps
Grounding clamps are a critical safety measure that protect welders from electric shocks. In addition,
a good grounding clamp will make it easier to start an arc and will protect your welder. The best
ground clamps are made of copper, not just lined with copper on the edges of the clamp.
Grounding clamps will be most effective if they maintain constant contact with the work piece. Some
welders modify their set ups by adding a large piece of copper cable to their clamps in order to
improve the amount of contact with the surface.
Explore Grounding Clamps
Clothing
No one wants to work on a welding project and discover sparks and flames on his/her shirt.
Synthetic shirts that aren't specifically made for welding work can be particularly dangerous for
welders when the sparks begin to fly.
Long sleeves are especially important for welding work since the rays from welding can cause
sunburn on exposed skin. There are many solutions for welding clothing, but oftentimes the
temperature of a work site or shop will determine what a welder wears.
Leather clothing is the safest choice, but it is also the warmest. Therefore, many welders wear
leather sleeves, longer gauntlet gloves, a leather apron, or a kind of modified welding bib with long
sleeves and an open back. Usually a cotton shirt is the best choice to wear under protective gear
since it's not as flammable as synthetic clothing.
Explore Safety Apparel and Baker's Work Wear
Safety Products
Depending on the nature of your work and your shop set up, your safety needs will vary. At the very
least every shop needs a fire extinguisher and some form of ventilation. Fume extraction systems
represent the best option, but many home welders can get by with an open garage door or a simple
ventilation system set up in a window. However, ventilation is not optional since certain welding
processes can give off toxic fumes depending on the materials being welded.
If welding at home, it's important to set up welding screens to protect passing pedestrians or fire
retardant barriers to prevent sparks from catching on any cloth, cardboard, or saw dust in the
garage. For particularly messy welding projects, these screens also save on clean up.
For shops or garages that have lots of fuel cannisters on hand, Baker's offers fuel storage solutions
that will keep them upright and safe. In a garage or shop where the unexpected can happen,
securing fuel and shielding everything from sparks is critical.
Explore Safety Products
The gear and products in this article are just some of the basics for welding, but welders will need to
purcahse shielding gas and other materials depending on their work. To find more of what you need
to weld, shop by category.
An electrode is an electrical conductor used to make contact with a nonmetallic part of a circuit (e.g.
a semiconductor, an electrolyte, a vacuum or air). The word was coined by William Whewell at the
request of the scientist Michael Faraday from two Greek words: elektron, meaning amber (from
which the word electricity is derived), and hodos, a way.[1][2]
The electrophore, invented by Johan Wilcke, was an early version of an electrode used to
study static electricity.[3]
Welding Electrode
Welding electrodes are installed in the weld head to touch and maintain contact with the workpieces
through the full weld schedule. The welding electrodes play three different roles in resistance welding:
maintaining uniform current density, concentrating current at welding points, and maintaining thermal
balance during welding.
Electrodes are available in many shapes. Electrode material and shape are determined by considering
the force necessary for welding and the thermal conductivity of the workpieces.
In conventional macro-welding, e.g. car body assembly, the electrodes are made of copper alloys and
usually water-cooled. However, in micro-welding, the electrodes are made of a wide variety of conductive
and refractory materials depending on the parts to be joined, and are air-cooled.
Types of Welding Electrodes
May 20, 2018 tvm@2017 0 Comments
Are you interested in knowing different welding electrodes? Then this article is surely for you. In this
article, you will get deep knowledge about welding electrode, types of welding electrodes and many
more. So, what are you waiting for? Let’s get started.
What is Welding Electrode?
A welder needs an electrode to generate an electric current to do arc welding. In welding, an electric
current is conducted through an electrode which is used to join the parent metals. When you keep
electrode tip near the parent metal electric current jumps from the electrode tip to the parent metal.
The main purpose of electrodes used in welding is to create an electric arc. These electrodes can be
positively charged anode or they can be negatively charged cathode.
Factors that you must consider before selecting welding electrodes:
1. The electrode rod should have greater tensile strength than the parent metals.
2. You have to consider joint design, shape, specifications of base metals and welding positions.
Types of Welding Electrodes
Basically, depending upon the process there are two types of welding electrodes:
1. Consumable Electrodes
2. Non-Consumable Electrodes
1. Consumable Electrodes
Consumable electrodes have low melting point. These types of welding electrodes are preferred to
use in Metal Inert Gas (MIG) welding. For making consumable electrodes, materials such as mild
steel and nickel steel are used. The one precaution that you must take is to replace consumable
electrodes after regular intervals. The only disadvantage of using such electrodes is that they don’t
have a large number of industry applications but at the same time they are easy to use and maintain.
Consumable electrodes are categorized as:
1. Bare Electrodes
2. Coated Electrodes
(i) Bare Electrodes
Bare electrodes are electrodes without any type of coating and mostly used in applications where
there is no need of coated electrode.
(ii) Coated Electrodes
Coated electrodes are classified according to the coating factor. Coating factor is the ratio of the
diameter of the electrode to the diameter of the core wire.
So, following are sub types of coated electrodes:
1. Light coated electrodes with coating factor of 1.25. Light coating applied to electrodes helps to
remove impurities such as oxides and phosphorous. Light coating also helps in enhancing arc
stability.
2. Medium coated electrodes with coating factor of 1.45.
3. Shielded arc or Heavily coated electrodes with coating factor ranging between 1.6 to 2.2. These
electrodes have a proper and well defined composition. The heavily coated electrodes are designed
in three types – electrodes with cellulose coating, electrodes with mineral coating and the
electrodes with coating of both cellulose as well as mineral coating.
Also Read:
Types of Welding Process – Everyone Should Know
Difference Between MIG and TIG Welding
Different Types of Welding Joints
2. Non-Consumable Electrodes
These types of welding electrodes are also referred to as Refractory electrodes. There are again two
sub-types of non-consumable electrodes:
1. Carbon or Graphite electrodes: It is made up of carbon and graphite and mostly used in the
applications of cutting and arc welding.
2. Tungsten electrodes: Basically, it is consists of tungsten as the name itself suggests and it is a nonfiller metal electrode.
As the name suggests, these types of welding electrodes are not consumed in the entire welding
process or we can say more appropriately that they do not melt during welding. But practically, due
to the vaporization and oxidation processes taking place during welding there is a little bit reduction
in the length of the electrode. The non-consumable electrodes have high melting point and are unable
to fill the gap in the workpiece. Non-consumable electrodes are made from materials such as pure
tungsten, graphite or carbon coated with copper. The melting point of carbon is 3350 degree Celsius
and that of Tungsten is 3422 degree Celsius. Non-consumable electrodes are used in Tungsten inert
gas welding (TIG) and carbon arc welding.
Important Characteristics of NonConsumable Electrodes:
1. While using non-consumable electrodes you have to use shielding gases. The shielding gases are
inert gases and the reason behind to use them is to protect welding area from oxygen and
surrounding atmosphere.
2. The non-consumable electrodes are usually made as cathode and the workpieces as anode.
Classification of Welding Electrodes
This classification is based on practical approach towards using and selecting welding electrodes.
The American Welding Society has classified electrodes in different formats for proper
understanding of different electrodes easily and to identify them comfortably.
Suppose we consider the electrode named as
E6018-X


Here the E indicates that this is an electrode.
The consecutive two digits after the letter E gives you the tensile strength of the electrode. This
tensile strength is measured in psi and this strength is 1000 times the given number. That means
here this tensile strength of the given electrode is 60,000 psi.




Here 1 indicates the welding position. The welding position is indicated by 1,2 and 4.
1 indicates flat, horizontal, vertical position.
2 indicates flat, horizontal position.
4 indicates flat, horizontal, vertically downward position.
The number 8 gives you information about the type of coating and current used. It also tells about
the penetration of electrode means the electrode may penetrate deep, low, medium.
The X in the E6018-X tell us about the additional specifications of an electrode. Here the term X is
not always mentioned. It is used only when an electrode has some additional features. This
classification is applicable to mild steel coated electrode. If you consider other types of electrodes,
the classification will be same but only the feature represented by X letter may vary.
Some additional properties represented by letter X:
-1: It indicates that the electrode is more ductile and has high toughness.
-M: It is comfortable for military applications and low moisture content.
-H4, -H8,-H16: All represents maximum diffusible hydrogen limit measured in millimetres per 100
Grams. For instance, -H4 = 4 mL per 100 grams.
Precautions that you must take while
handling welding electrodes:
1. You must always keep electrodes dry.
2. As moisture destroys electrode coating and is very harmful for electrodes. So, as soon as electrodes
get dried, you must keep welding electrodes in moisture free environment. There are various
containers available which give you moisture free experience.
3. Last but not the least, never bend the electrodes as bending can harm electrode coating.
In short, after reading this article you must get a clear information about different types of welding
electrodes, classification system of welding electrodes, etc. Hope this article will help you. Share this
knowledge maximum because sharing is caring.
What is the difference between electrode, filler
metal and welding rod?
8 Answers
Nivas Ramachandiran, former Welding Engineer at Wheels India Limited (2011-2012)
Answered Feb 18, 2016 · Upvoted by Miranda Marcus, Applications Engineer at EWI specializing in
Plastic Joining
Electrode: A part of the electical circuit (Normally positive terminal is connected to it)
Filler metal: Metallic wire used to fill the gap between the base metals to be joined. It
need not be a part of the electrical circuit.
Welding Rod: A colloquial name of electodes/filler metal used in SMAW process.
An electrode could be either consumable or non-consumable. (i.e) during welding, the
metal reqd to fill the gap could be provided by the electrode itself
(SMAW, GMAW,SAW processes).
In GTAW process, the tungsten electode is non-consumable & thats why it is called
as autogenous welding. Here the tungsten electrode acts only as an electrode (part of
electrical circuit) and does not provide the weld metal required to fill the gap.
Fig 1: Two plates being welded by GTAW (TIG) process
In the fig 1 it could be seen, the tungsten electrode is a part of electical circuit. The filler
rod/wire is introduced into the arc. It melts at the high temperature and fills the gap
between the base metals.
Fig2: Two plates being welded by GMAW (MIG) process
In fig 2 it could be seen, the filler rod is a part of the electrical circuit (i.e) it also acts as
electode. Since it is consumable, it is continuously provided from a spool (not shown in
the figure) by the drive rolls.
A welding rod is a colloquial name given for the electrode which also acts as a filler
material in SMAW process. Here, the flux coating over the elcetrode provides the
necessary shielding required for the weld pool from the atmosphere whereas in the
GMAW & GTAW processes, an external gas shielding is required. But the length of the
continuous weld bead is restricted to the length of the welding rod.
Fig3: E7018 electodes (welding rod) used in SMAW process
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Ask New Question
Sanjay Sharma, Associate Professor, Mechanical Engineering (2004-present)
Answered May 23, 2017 · Author has 75 answers and 66.2k answer views
Electrodes are the tools used to generate arc with the opposite member. They are
consumable and coated most of the time. The inner rod provides extra metal needed for
the welding area and coating provide the necessary flux material. In this case no extra
filler metal is needed, and welding rod will be the inner rod of the electrode.
When the electrode used is of non consumable type, then extra metal is to be added with
the help of filler metal rod. This is to be melted by the arc formed to fill in the welding
groove. This is also called as Welding Rod.
5.6k Views · View 6 Upvoters · View Sharers · Answer requested by Keerthi Vasan
Jimmie Perry III, Owner of the best businesses in the world
Answered Jan 11, 2019 · Author has 125 answers and 13.4k answer views
All About Consumables
One of the biggest mysteries of the welding universe is how to understand consumables
and what to use. The thing to keep in mind is that there are a wide number of
consumables to choose from but you don’t have to make it a confusing process.
Consumables are the things that welders use up and need to replace every so often. The
rate of replacement and materials that you’ll need to purchase depends on a variety of
factors. These factors are:
1.
2.
3.
4.
5.
6.
The type of metal being welded
What you’re welding
The size and style of the groove
The code requirements
Position you’re welding in
The environment you’re welding in
Now that consumables have been standardized by the AWS the job of a welder has
gotten much simpler. These standards make sure that your welds are up to code and
have the correct materials. Although manufacturers have their own models and brands,
you can compare your models to the basic industry classifications. An example of this is
a welding rod is titled the “Stickweld” it will have the same classifications of the “E6010”. It’s a great idea for one to focus on learning the basic classifications of filler rods,
electrodes, and wire that are needed to perform their basic duties. Since many products
will have certain specifications and you’ll need to go search for them occasionally, it will
help if you know their classifications.
If you consider yourself to be a newer welder you probably helps to understand the
nuances of what both an electrode and filler rod. It also helps to understand that these
differences don’t all matter in certain welding processes. For example, in stick welding
electrodes and filler are rod are considered the same thing. However, the filler rod is
energized when electricity from the welding machine while also being attached to a
metal clamp. This event produces the arc, which in turn heats up rather quickly. The
heat generated by the arc is what melts the filler rod into joint in the metal being weld.
It’s a well-known fact that stick welding is a bit more of a challenge to learn, which is the
reason why there is so much opportunity in this market.
Classifications for Stick Electrodes
These metals are what you can find stick electrodes being sold for: Stick electrodes are
classified according to their metal type. A very common classification is AWS
A5.1/A5.1M: This is the specification for Carbon Steel Electrodes for SMAW. A couple of
examples are E-7018 or E6010 which are used by Pipe welders.
An explanation of the numbers is below:
E-Electrode
70 – is the tensile strength of the metal being welded, which is measured
according to PSI.
1 – This means that it will be the most difficult to weld in any position. (1 is
any position 2 is horizontal and flat; 3 is flay only; 4 is overhead, horizontal,
vertical down and flat)
8 – The fact that this number is also combined with a third number
occasional can make interpreting it a bit difficult. This number has the sole
purpose of telling you the flux/deoxidizers or other ingredients that may be
in the coating of the electrode.
The design of the coating is what determines the power source polarity and the welding
position. T properly read the coating you have to read both of the numbers together. The
below chart discusses the materials used for each welding position as well as the types
you can use for each rod designation.
Learn more about welding here
Types of Electrodes Used in
Welding
By Jay Leone; Updated April 24, 2017
welding project image by leemarusa from Fotolia.com
Consumers have access to many different types of welding electrodes. Each offers
features that make it ideal for a certain application. In welding applications, electricity is
drawn through an electrode, creating an arc of electricity at the tip of the electrode.
Welds are created when the electric arc at the tip of an electrode is drawn onto a work
piece. Many types of electrodes melt and are transferred onto a work piece, creating a
metal filler, while others do not melt and simply provide a location for an electric arc.
6010 Electrodes
This type of electrode is often employed for general welding applications that do not call
for any special features. They also are used on farm equipment, piping, wrought iron
and road equipment. According to Metal Web News, 6011 electrodes create welds with
a minimum tensile strength of around 60,000 pounds per square inch (psi). Welders can
hold this type of electrode in any position to create a proper weld. 6010 electrodes are
designed for use under direct currents (DC). According to Welding Tips and Tricks,
6010 electrodes feature a high cellulose sodium outer coating.
6013 Electrodes
6013 electrodes are relatively easy to use. They create a softer arc that is ideal for use
on sheet metal. This type of electrode is often employed for general repair on thinner
materials. 6013 electrode welds offer around a 60,000 psi minimum tensile strength,
according to Metal Web News. These electrodes can be held in any position and are
used under either direct or alternating currents (AC). 6013 electrodes feature a high
titania potassium outer coating, according to Welding Tips and Tricks.
7018 Electrodes
The 7018 electrode is often referred to as a “low hydrogen electrode” that features a low
moisture coating, which reduces the level of hydrogen that seeps into a weld. This type
of electrode produces high-quality, crack-resistant weld points with medium penetration.
These electrodes must remain dry before use. The minimum weld tensile strength
produced by this type of electrode is around 70,000 psi, according to Metal Web News.
7018 electrodes also can be held in any position while welding. 7018 electrodes are
engineered to operate under either direct currents or alternating currents. According to
Welding Tips and Tricks, this type of electrode features an iron powder, low hydrogen
outer coating.
Electrode Holder. An electrode holder, commonly called a stinger, is a clamping device for
holding theelectrode securely in any position. The weldingcable attaches to the holder through
the hollow insulated handle.
Welding Rods Explained!
There are a lot of different welding electrodes and wires out there. In
the field, welding electrodes are usually referred to as "welding rods"
so I will use that term here.
"Stick Welding" is also the term of choice in the field for SMAW, the
acronym for Shielded Metal Arc Welding.
Stick welding used to be done with a bare welding rod. It was very
difficult, and could only be used in the flat position. If you've ever
stuck a rod with flux on it, you can only imagine how many times
they stuck bare rods! If the rod gets too close to the base metal it
will decrease the voltage causing the arc to go out.
Click here to view our welding ovens and to learn
about the benefits of proper storage!
Sticking the welding rod is where the rod instead of melting like it should, sticks to the base metal.
There is not enough current to melt it, but enough for it to stick. One way of getting it loose is
immediately jerking the rod away from the base metal. If that doesn't work, you have to unclamp the
rod, and then break it off.
EVERYONE sticks welding rods when they're learning, and even old salts like me stick it every once
and a while. I've always thought it was called stick welding because the electrode looked like a stick,
but I read on Miller's website once that it's called stick welding because so many people stick it when
learning.
If you jerk the "stinger" (electrode holder) quick enough you can break the rod off of the base metal
and re-strike your arc. But if it stays there too long and gets too hot, it will easily stick again and
should be put down and allowed to cool.
Many times when it sticks, the jerking away, or breaking loose of the rod will cause flux to come off of
the end. That makes it really hard to strike and arc again without it sticking. Sticking the rod is SOME
KIND of frustrating. I have a punching bag up in my shop for students to acquire good eye/hand
coordination, but it's also a way for them to go let off some steam when they need to.
One quick fix is to long-arc (hold the rod up off of the plate about a quarter inch) the welding rod and
burn the bare metal off until it reaches the flux. . It helps to turn the machine up to warp 10 (in other
words crank that baby up) when burning it off. If you don't do that, it will almost always stick again to
the bare rod that you're trying to fix.
That's one reason you really need to keep your welding rods, especially 7018 low-hydrogen rods, in
rod ovens. If you don't, besides getting moisture in the flux, which causes porosity, or worm holes;
the flux can become brittle and flake off.
In another article, I'll explain about the most common kinds of welding rods used in the shop and
field, as well as explaining some of the less used ones.
Term
Main definition
ABRASIVE WEAR
Wear due to hard particles or hard protuberances forced against and moving alon
AC (Alternating Current)
Unit of measurement Hz (cycles per second).
ACCELERATED LIFE
TEST
A test method designed to force products to fail more quickly than they would und
acceleration of failures with the single purpose of quantification of the life charact
ACCELERATOR
Chemical which speeds the vulcanization of an elastomer so that it takes place in
activator leaves off an accelerator is often used in conjunction with a catalyst hard
ACCUMULATOR
A vessel in which a gas is enclosed and compressed by the liquid in a hydraulic s
system when needed. Types available are bladder piston and diaphragm.
ACME THREAD
Screw thread profile used in translational applications such as those involving lar
better strength than a 60 degree V-form thread while overcoming the problems w
degree thread angle with flat apex and valley.
ACTUATOR
A device attached to a valve to provide the operation. Motion energy can be pneu
ADAPTER SPOOL
An extension which is added to a short end-to-end valve to conform to either stan
Piece.
Term
Main definition
ADAPTION
A term used to describe the interface between the valve and the valve actuator w
top-work flange. Can be a simple plate or a fabricated pedestal.
ADDITIVE
A substance added in small amounts to an elastomeric compound to improve stre
improve strength or a plasticizer to aid flexibility and processability.
AED (Anti Explosive
Decompression)
See Explosive Decompression.
AGA (American Gas
Association)
A trade association which represents local energy utility companies that deliver n
AGING
Change in rubber characteristics over time brought about by environmental facto
covered by ISO 188 and by ASTM D573.
AIR RECEIVER
A container (vessel) in which gas is stored under pressure as a source of pneum
AISI (American Iron and
Steel Institute)
An association of steel producers which sets standards for the chemical and phys
pipe tubing sheet strip and wire. www.steel.org
(Mechanical engineering: Manufacturing and assembly)
Shielded metal arc welding is a process in which a
coated wire is melted to fill spaces between parts. The
molten coatingfloats to the surface of the molten metal to protect it
from the atmosphere.
Shielded metal arc welding is also called stick welding and it uses the simplest equipment of
any arc welding process.
In shielded metal arc welding, an electrical circuit is established between the workpiece and
the welding electrode.
Shielded metal arc welding is a process in which a coated wire is melted to fill spaces
between parts. The molten coating floats to the surface of the molten metal to protect it from
the atmosphere.
Welding Terms Glossary
Abrasive – Slag used for cleaning or surface roughening.
Active Flux – Submerged-arc welding flux from which the amount of elements deposited in the weld metal is dependent
upon welding conditions, primarily arc voltage.
Adhesive Bonding – Surfaces, solidifies to produce an adhesive bond.
Air Carbon Arc Cutting – An arc cutting process in which metals to be cut are melted by the heat of carbon arc and the
molten metal is removed by a blast of air.
All-Weld-Metal Test Specimen – A test specimen with the reduction section composed wholly of weld metal.
Alloying – Adding a metal or alloy to another metal or alloy.
Alternating Current (AC) – Electric current that reverses direction periodically, usually many times per second.
Annealed Condition – A metal or alloy that has been heated and then cooled to remove internal stresses and to make
the material less brittle.
Arc Blow – The deflection of an electric arc from its normal path because of magnetic forces.
Arc Cutting – A group of thermal cutting processes that severs or removes metal by melting with the heat of an arc
between an electrode and the work piece.
Arc Force – The axial force developed by an arc plasma.
Arc Gouging – An arc cutting procedure used to form a bevel or groove.
Arc Length – The distance from the tip of the electrode or wire to the work piece.
Arc Time – The time during which an arc is maintained.
Arc Voltage – The voltage across the welding arc.
Arc Welding – A group of welding processes which produces coalescence of metals by heating them with an arc, with or
without the application of pressure and with or without the use of filler metal.
Arc Welding Deposition Efficiency (%) – The ratio of the weight of filler metal deposited to the weight of filler metal
melted.
Arc Welding Electrode – A part of the welding system through which current is conducted that ends at the arc.
As-Welded – The condition of the weld metal, after completion of welding, and prior to any subsequent thermal or
mechanical treatment.
Atomic Hydrogen Welding – An arc welding process which produces coalescence of metals by heating them with an
electric arc maintained between two metal electrodes in an atmosphere of hydrogen.
Austenitic – Composed mainly of gamma iron with carbon in solution.
Autogenous Weld – A fusion weld made without the addition of filler metal.
Automatic – The control of a process with equipment that requires little or no observation of the welding and no manual
adjustment of the equipment controls.
Back Gouging – The removal of weld metal and base metal from the other side of a partially welded joint to assure
complete penetration upon subsequent welding from that side.
Backfire – The momentary recession of the flame into the welding or cutting tip followed by reappearance or complete
extinction of the flame.
Backhand Welding – A welding technique where the welding torch or gun is directed opposite to the direction of welding.
Backing – A material (base metal, weld metal, or granular material) placed at the root of a weld joint for the purpose of
supporting molten weld metal.
Backing Gas – A shielding gas used on the underside of a weld bead to protect it from atmospheric contamination.
Backing Ring – Backing in the form of a ring, generally used in the welding of pipe.
Back-Step Sequence – A longitudinal sequence in which the weld bead increments are deposited in the direction opposite
to the progress of welding the joint.
Base Metal (material) – The metal (material) to be welded, brazed, soldered, or cut. See also substrate.
Bend Radius – Radius of curvature on a bend specimen or bent area of a formed part. Measured on the inside of a bend.
Bevel – An angled edge preparation.
Blanking – Process of cutting material to size for more manageable processing.
Braze Welding – A method of welding by using a filler metal, having a liquidus above 840 °F (450 °C) and below the
solidus of the base metals.
Brazing – A group of welding processes which produces coalescence of materials by heating them to a suitable
temperature and by using a filler metal, having a liquidus above 840 °F (450 °C) and below the solidus of the base
materials. The filler metal is distributed between the closely fitted surfaces of the joint by capillary attraction.
Burr – A rough ridge, edge, protuberance, or area left on metal after cutting, drilling, punching, or stamping.
Buttering – A form of surfacing in which one or more layers of weld metal are deposited (for example, a high alloy weld
deposit on steel base metal which is to be welded to a dissimilar base metal). The buttering provides a suitable transition
weld deposit for subsequent completion of the butt weld on the groove face of one member.
Butt Joint – A joint between two members lying in the same plane.
Camber – Deviation from edge straightness, usually the greatest deviation of side edge from a straight line.
Cap Pass – The final pass of a weld joint.
Carrier Gas – In thermal spraying, the gas used to carry powdered materials from the powder feeder or hopper to the
gun.
Capillary Action – The action by which the liquid surface is elevated or depressed where it contacts a solid because the
liquid molecules are attracted to one another and to the solid molecules.
Cladding – A thin (> 0.04") layer of material applied to the base material to improve corrosion or wear resistance of the
part.
Clad Metal – A composite metal containing two or three layers that have been welded together. The welding may have
been accomplished by roll welding, arc welding, casting, heavy chemical deposition, or heavy electroplating.
Coalescence – The uniting of many materials into one body.
Coherent – Moving in unison.
Cold Lap – Incomplete fusion or overlap.
Collimate – To render parallels to a certain line or direction.
Complete Fusion – Fusion that has occurred over the entire base material surfaces intended for welding, and between all
layer and passes.
Complete Joint Penetration – Joint penetration in which the weld metal completely fills the groove and is fused to the
base metal throughout its total thickness.
Constant Current Power Source – An arc welding power source with a volt-ampere output characteristic that produces a
small welding current change from a large arc voltage change.
Constant Voltage Power Source – An arc welding power source with a volt-ampere output characteristic that produces a
large welding current change from a small arc voltage change.
Contact Tube – A system component that transfers current from the torch gun to a continuous electrode.
Contact Resistance – The resistance in ohms between the contacts of a relay, switch, or other device when the contacts
are touching each other.
Contact Tube – A device which transfers current to a continuous electrode
Covered Electrode – A filler metal electrode used in shielded metal-arc welding, consisting of a metal-wire core with a
flux covering.
Crater – In arc welding, a depression on the surface of a weld bead.
Crater Crack – A crack in the crater of a weld bead.
Cryogenic – Refers to low temperatures, usually -200 o (-130 o) or below.
Cutting Attachment – A device for converting an oxy-fuel gas-welding torch into an oxy-fuel cutting torch.
Cylinder – A portable container used for transportation and storage of a compressed gas.
Defect – A discontinuity or discontinuities that by nature or accumulated effect (for example, total crack length) renders a
part or product unable to meet minimum applicable acceptance standards or specifications.
Density – The ratio of the weight of a substance per unit volume; e.g. mass of a solid, liquid, or gas per unit volume at a
specific temperature.
Deposited Metal – Filler metal that has been added during welding, brazing or soldering.
Deposition Efficiency – In arc welding, the ratio of the weight of deposited metal to the net weight of filler metal
consumed, exclusive of stubs.
Deposition Rate – The weight of material deposited in a unit of time. It is usually expressed as pounds/hour (lb/h) or
kilograms per hour (kg/h).
Depth of Fusion – The distance that fusion extends into the base metal or previous pass from the surface melted during
welding.
Dew Point – The temperature and pressure at which the liquefaction of a vapor begins. Usually applied to condensation of
moisture from the water vapor in the atmosphere.
Dilution – The change in chemical composition of a welding filler material caused by the admixture of the base material or
previously deposited weld material in the deposited weld bead. It is normally measured by the percentage of base material
or previously deposited weld material in the weld bead.
Direct Current – Electric current that flows in one direction.
Direct Current Electrode Negative (DCEN) – The arrangement of direct current arc welding leads in where the
electrode is the negative pole and work-piece is the positive pole of the welding arc.
Direct Current Electrode Positive (DCEP) – The arrangement of direct current arc welding leads in where the electrode
is the positive pole and work-piece is the negative pole of the welding arc.
Duty Cycle – The percentage of time during a time period that a power source can be operated at rated output without
overheating.
Dynamic Load – A force exerted by a moving body on a resistance member, usually in a relatively short time interval.
Electrode Extension – The length of electrode extending beyond the end of the contact tube.
Electrode Holder – A welding process that produces coalescence of metals with the heat obtained from a concentrated
beam composed primarily of high velocity electrons
Electron Beam Welding – A welding process producing coalescence of metals with molten slag which melts the filler
metal and the surfaces of the work to be welded. The molten weld pool is shielded by the slag, which moves along the full
cross section of the joint as welding progresses.
Electroslag Welding – A welding process producing coalescence of metals with molten slag which melts the filler metal
and the surfaces of the work to be welded. The molten weld pool is shielded by the slag, which moves along the full cross
section of the joint as welding progresses.
Eutectoid Composition – A mixture of phases whose composition are determined by the eutectoid point in the solid
region of an equilibrium diagram and whose constituents are formed by eutectoid reaction.
Facing Surface – The surfaces of materials in contact with each other and joined or about to be joined together.
Filler Material – The material to be added in making a welded, brazed, or soldered joint.
Fillet Weld – A weld of approximately triangular cross section that joins two surfaces approximately at right angles to
each other in a lap joint, T-joint, or corner joint.
Filter Plate – A transparent plate tinted in varying darkness for use in goggles, helmets and hand shields to protect
workers from harmful ultraviolet, infrared and visible radiation.
Flame Spraying – A thermal spraying process using an oxy-fuel gas flame as the source of heat for melting the coating
material.
Flammable Range – The range over which a gas at normal temperature (NTP) forms a flammable mixture with air.
Flat Welding Position – A welding position where the weld axis is approximately horizontal and the weld face lies in an
approximately horizontal plane.
Flashback – A recession of the flame into or back of the mixing chamber of the torch.
Flashback Arrestor – A device to limit damage from a flashback by preventing the propagation of the flame front beyond
the point at which the arrestor is installed.
Flashing – The violent expulsion of small metal particles due to arcing during flash butt welding.
Flux – Material used to prevent, dissolve, or facilitate removal of oxides and other undesirable surface substances.
Flux Cored Arc Welding (FCAW) – An arc welding process that produces coalescence of metals by means of tubular
electrode. Shielding gas may or may not be used.
Friction Welding – A solid welding process which produces coalescence of material by the heat obtained from a
mechanically induced sliding motion between rubbing surfaces. The work parts are held together under pressure.
Friction Stir Welding – A solid-state welding process, which produces coalescence of material by the heat obtained from
a mechanically induced rotating motion between tightly butted surfaces. The work parts are held together under pressure.
Forehand Welding – A welding technique where the welding torches or gun is pointed toward the direction of welding.
Fusion – The melting together of filler metal and base metal (substrate), or of base metal only, which results in
coalescence.
Gas Metal Arc Welding (GMAW) – An arc welding process where the arc is between a continuous filler metal electrode
and the weld pool. Shielding from an externally supplied gas source is required.
Gas Tungsten Arc Welding (GTAW) – An arc welding process where the arc is between a tungsten electrode (nonconsumable) and the weld pool. The process is used with an externally supplied shielding gas.
Gas Welding – Welding with the heat from an oxy-fuel flame, with or without the addition of filler metal or pressure.
Globular-Spray Transition Current – In GMAW/Spray Transfer, the value at which the electrode metal transfer changes
from globular to spray mode as welding current increases for any given electrode diameter.
Globular Transfer – In arc welding, a type of metal transfer in which molten filler metal is transferred across the arc in
large droplets.
Groove Weld – A weld made in a groove between two members. Examples: single V, single U, single J, double bevel etc.
Hard-Facing – Surfacing applied to a workplace to reduce wear.
Heat-Affected Zone – That section of the base metal, generally adjacent to the weld zone, whose mechanical properties
or microstructure, have been altered by the heat of welding.
Hermetically Sealed – Airtight. Heterogenous – A mixture of phases such as: liquid-vapor or solid-liquid-vapor.
Hot Crack – A crack formed at temperatures near the completion of weld solidification.
Hot Pass – In pipe welding, the second pass which goes over the root pass.
Inclined Position – In pipe welding, the pipe axis angles 45 degrees to the horizontal position and remains stationary.
Incomplete Fusion – A weld discontinuity where fusion did not occur between weld metal and the joint or adjoining weld
beads.
Incomplete Joint Penetration – A condition in a groove weld where weld metal does not extend through the joint
thickness.
Inert Gas – A gas that normally does not combine chemically with the base metal or filler metal.
Intergranular Penetration – The penetration of filler metal along the grain boundaries of a base metal.
Interpass Temperature – In a multi-pass weld, the temperature of the weld area between passes.
Ionization Potential – The voltage required to ionize (add or remove an electron) a material.
Joint – The junction of members or the edges of members that are to be joined or have been joined.
Kerf – The width of the cut produced during a cutting process.
Keyhole – A technique of welding in which a concentrated heat source penetrates completely through a work-piece
forming a hole at the leading edge of the molten weld metal. As the heat source progresses, the molten metal fills in
behind the hole to form the weld bead.
Lap Joint – A joint between two overlapping members in parallel planes.
Laser – A device that provides a concentrated coherent light beam. Laser is an acronym for Light Amplification by
Stimulated Emission of Radiation.
Laser Beam Cutting – A process that severs material with the heat from a concentrated coherent beam impinging upon
the work-piece.
Laser Beam Welding – A process that fuses material with the heat from a concentrated coherent beam impinging upon
the members to be joined.
Leg of Fillet Weld – The distance from the root of the joint to the toe of the fillet weld.
Liquidus – The lowest temperature at which a metal or an alloy is completely liquid.
Mandrel – A metal bar serving as a core around which other metals are cast, forged, or extruded, forming a true, center
hole.
Manifold – A multiple header for interconnection of gas or fluid sources with distribution points.
Martensitic – An interstitial, super-saturated solid solution of carbon in iron, having a body-centered tetragonal lattice.
Manual Welding – A welding process where the torch or electrode holder is manipulated by hand. MIG – See Gas Metal
Arc Welding (GMAW).
Mechanical Bond – The adherence of a thermal-spray deposit to a roughened surface by particle interlocking.
Mechanized Welding – Welding with equipment where manual adjustment of controls is required in response to
variations in the welding process. The torch or electrode holder is held by a mechanical device.
Melting Range – The temperature range between solidus and liquidus.
Melt-Through – Visible reinforcement produced on the opposite side of a welded joint from one side.
Metal Cored Arc Welding – A tubular electrode process where the hollow configuration contains alloying materials.
Metal Cored Electrode – A composite tubular electrode consisting of a metal sheath and a core of various powdered
materials, producing no more than slag islands on the face of the weld bead. External shielding is required.
Molecular Weight – The sum of the atomic weights of all the constituent atoms in the molecule of an element or
compound.
Monochromatic – The color of a surface that radiates light, containing an extremely small range of wavelengths.
Neutral Flame – An oxy-fuel gas flame that is neither oxidizing nor reducing.
Open-Circuit Voltage – The voltage between the output terminals of the welding machine when no current is flowing in
the welding circuit.
Orifice Gas – In plasma arc welding and cutting, the gas that is directed into the torch to surround the electrode. It
becomes ionized in the arc to form the plasma and issues from the orifice in the torch nozzle as the plasma jet.
Oxidizing Flame – An oxy-fuel gas flame having an oxidizing effect (excess oxygen).
Peening – The mechanical working of metals using impact blows.
Pilot Arc – A low current continuous arc between the electrode and the constricting nozzle of a plasma torch that ionizes
the gas and facilitates the start of the welding arc.
Plasma – A gas that has been heated to at least partially ionized condition, enabling it to conduct an electric current.
Plasma Arc Cutting (PAC) – An arc cutting process using a constricted arc to remove the molten metal with a highvelocity jet of ionized gas from the constricting orifice.
Plasma Arc Welding (PAW) – An arc welding process that uses a constricted arc between a non-consumable electrode
and the weld pool (transferred arc) or between the electrode and the constricting nozzle (non-transferred arc). Shielding is
obtained from the ionized gas issuing from the torch.
Plasma Spraying (PSP) – A thermal spraying process in which a non-transferred arc is used to create an arc plasma for
melting and propelling the surfacing material to the substrate.
Plug Weld – A circular weld made through a hole in one member of a lap or T joint.
Porosity – A hole-like discontinuity formed by gas entrapment during solidification.
Post-Heating – The application of heat to an assembly after welding, brazing, soldering, thermal spraying, or cutting
operation.
Postweld Heat Treatment – Any heat treatment subsequent to welding.
Preform – The initial press of a powder metal that forms a compact.
Preheating – The application of heat to the base metal immediately before welding, brazing, soldering, thermal spraying,
or cutting.
Preheat Temperature – The temperature of the base metal immediately before welding is started.
Procedure Qualification – Demonstration that a fabricating process, such as welding, made by a specific procedure can
meet given standards.
Pull Gun Technique – Same as backhand welding.
Pulsed Power Welding – Any arc welding method in which the power is cyclically programmed to pulse so that the
effective but short duration values of a parameter can be utilized. Such short duration values are significantly different
from the average value of the parameter. Equivalent terms are pulsed voltage or pulsed current welding.
Pulsed Spray Welding – An arc welding process variation in which the current is pulsed to achieve spray metal transfer
at average currents equal to or
less than the globular to spray transition current.
Push Angle – The travel angle where the electrode is pointing in the direction of travel.
Rake Angle – Slope of a shear knife from end to end.
Reducing Flame – A gas flame that has a reducing effect, due to the presence of excess fuel.
Reinforcement – Weld metal, at the face or root, in excess of the metal necessary to fill the joint.
Residual Stress – Stress remaining in a structure or member, as a result of thermal and/or mechanical treatment. Stress
arises in fusion welding primarily because the melted material contracts on cooling from the solidus to room temperature.
Reverse Polarity – The arrangement of direct current arc welding leads with the work as the negative pole and the
electrode as the positive pole of the welding arc.
Root Opening – A separation at the joint root between the work pieces.
Root Crack – A crack at the root of a weld.
Self-Shielded Flux Cored Arc Welding (FCAW-S) – A flux-cored arc welding process variation in which shielding gas is
obtained exclusively from the flux within the electrode.
Shielded Metal Arc Welding (SMAW) – A process that welds by heat from an electric arc, between a flux-covered metal
electrode and the work. Shielding comes from the decomposition of the electrode covering.
Shielding Gas – Protective gas used to prevent atmospheric contamination.
Soldering – A joining process using a filler metal with a liquidus less than 840 °F and below the solidus of the base metal.
Solid State Welding – A group of welding processes which produces coalescence at temperatures essentially below the
melting point of the base materials being joined, without the addition of a brazing filler metal. Pressure may of may not be
used.
Solidus – The highest temperature at which a metal or alloy is completely solid.
Spatter – Metal particles expelled during welding that do not form a part of the weld.
Spray Transfer – In arc welding, a type of metal transfer in which molten filler metal is propelled axially across the arc in
small droplets.
Standard Temperature and Pressure (STP) – An internationally accepted reference base where standard temperature
is 0 °C (32 °f) and standard pressure is one atmosphere, or 14.6960 psia.
Stick-Out – The length of unmelted electrode extending beyond the end of the contact tube in continuous welding
processes.
Straight Polarity – Direct current arc welding where the work is the positive pole.
Stress Relief Heat Treatment – Uniform heating of a welded component to a temperature sufficient to relieve a major
portion of the residual stresses.
Stress Relief Cracking – Cracking in the weld metal or heat affected zone during post-weld heat treatment or high
temperature service.
Stringer Bead – A weld bead made without transverse movement of the welding arc.
Submerged Arc Welding – A process that welds with the heat produced by an electric arc between a bare metal
electrode and the work. A blanket of granular fusible flux shields the arc.
Substrate – Any material upon which a thermal-spray deposit is applied.
Synergistic – An action where the total effect of two active components in a mixture is greater than the sum of their
individual effects.
Tack Weld – A weld made to hold parts of a weldment in proper alignment until the final welds are made.
Tenacious – Cohesive, tough.
Tensile Strength – The maximum stress a material subjected to a stretching load can withstand without tearing.
Thermal Conductivity – The quantity of heat passing through a material.
Thermal Spraying – A group of processes in which finely divided metallic or non-metallic materials are deposited in a
molten or semimolten condition to form a coating.
Thermal Stresses – Stresses in metal resulting from non-uniform temperature distributions.
Thermionic – The emission of electrons as a result of heat.
Throat – In welding, the area between the arms of a resistance welder. In a press, the distance from the slide centerline
to the frame, of a gap-frame press.
TIG Welding – See Gas Tungsten Arc Welding (GTAW).
Torch Standoff Distance – The dimension from the outer face of the torch nozzle to the work piece.
Transferred Arc – In plasma arc welding, a plasma arc established between the electrode and the work-piece.
Underbead Crack – A crack in the heat-affected zone generally not extending to the surface of the base metal.
Undercut – A groove melted into the base plate adjacent to the weld toe or weld root and left unfilled by weld metal.
Vapor Pressure – The pressure exerted by a vapor when a state of equilibrium has been reached between a liquid, solid
or solution and its vapor. When the vapor pressure of a liquid exceeds that of the confining atmosphere, the liquid is
commonly said to be boiling.
Viscosity – The resistance offered by a fluid (liquid or gas) to flow.
Weldability – The capacity of a material to be welded under the fabrication conditions imposed into a specific, suitably
designed structure and to perform satisfactorily in the intended service.
Weld Bead – The metal deposited in the joint by the process and filler wire used.
Welding Leads – The work piece lead and electrode lead of an arc welding circuit.
Welding Wire – A form of welding filler metal, normally packaged as coils or spools, that may or may not conduct
electrical current depending upon the welding process used.
Weld Metal – The portion of a fusion weld that has been completely melted during welding.
Weld Pass – A single progression of welding along a joint. The result of a pass is a weld bead or layer.
Weld Pool – The localized volume of molten metal in a weld prior to its solidification as weld metal.
Weld Puddle – A non-standard term for weld pool.
Weld Reinforcement – Weld metal in excess of the quantity required to fill a joint.
Welding Sequence – The order in which weld beads are deposited in a weldment.
Wetting – The phenomenon whereby a liquid filler metal or flux spreads and adheres in a thin continuous layer on a solid
base metal.
Wire Feed Speed – The rate at which wire is consumed in welding.
Work Lead – The electric conductor between the source of arc welding current and the work.
MIG – ‘MIG’ stands for ‘Metal Inert Gas’ welding, but you might also see it referred to as
‘GMAW’ (‘Gas Metal Arc Welding’), or ‘MAG’ (‘Metal Active Gas’ welding). This is one of
the most common welding techniques – and one of the easiest to learn – so it’s great for
both beginners and large scale production.
MIG uses a consumable electrode and an argon-carbon dioxide shielding gas to create
strong welds on both thin and thick sheets of metal.
TIG – ‘TIG’ stands for ‘Tungsten Inert Gas’ welding, which is the same as ‘GTAW’ (‘Gas
Tungsten Arc Welding’). On paper TIG seems quite similar to MIG, except that the
electrode is non-consumable and the shielding gas typically has an argon-helium
composition.
TIG is a more difficult process to master than MIG as it needs a more precise technique.
As a result, it’s usually used by more experienced welders or for delicate projects which
need a clean finish.
FCAW – ‘FCAW’ stands for ‘Flux-Cored Arc Welding’. This process uses different
equipment to MIG and TIG welding, because although the electrode is a continuouslyfed consumable one (like with MIG), it has a flux at its core. This flux eliminates the
need for a separate shielding gas, which means that it’s suitable for outdoor projects
and windy conditions.
FCAW can produce dangerous gases, so it’s essential to wear adequate protection
such as a welding helmet. However, if proper care is taken with safety as well as
technique, then FCAW is a brilliantly fast, portable process which is ideal for
manufacturing.
SMAW – ‘SMAW’ stands for ‘Shielded Metal Arc Welding’, but you might commonly hear
it being referred to as ‘stick welding’. Like FCAW, SMAW uses flux to protect the weld
pool from damaging atmospheric gases – the only difference is that in SMAW the flux
coats the electrode, whereas with FCAW it’s at the center.
Shop Tools <
Besides a welding machine, cutting torch and grinder, welders use a few
hand tools and clamping devices for their projects. Here's a look at
some of the more common items you'll find around a metal shop:
--Chipping Hammer, Wire Brush and Hand File
In stick welding and a few other processes, slag removal takes place
after each weld bead is deposited. The welder uses a chipping hammer
that's 8-10 inches long to gently dislodge the the slag from the weld
surface. Then he or she uses a wire brush to wipe away the chips and
dust away from the weld. Otherwise, that material would get entombed
when a cover pass is made.
Notice the spiral on the handle of the chipping hammer. This isn't a
decorative touch, but a way to keep the user's hand from making direct
contact with any heat conducting up through the handle. Wire brushes
have steel or stainless steel bristles, with a wooden or heat-resistant
plastic base that doesn't absorb or conduct heat.
A hand file is used for smoothing over grindededges and to remove
burrs from the metal. Since it'simportant to have good fit-up between
weld plates, a file also allows you to achieve a little more precision that a
grinder provides. Remember to use stainless steel files for that metal.
Special files are made for aluminum.
- - -- - --- Vice Grips and Pliers
After welding on a metal object, it may be too hot to handle with gloves,
so welders pick it up or reposition it using pliers. Vice grips, like those
featured above left, get a firmer grip on an object. You can often use this
simple pair of vice grips in place of a clamp, or to hold small metal
plates or objects against a stationary grinder or sander. Even cold metal
can get toasty fast on the grinding wheel, so the tool insulates your
hand from the heat.
The photo above right features a pair of MIG pliers. These cut spool
wire. The needlenose teeth are used to clean out carbon build-up and
other debris inside the nozzle of a MIG gun, as well as to grip wire.
---
Clamps
When welding a joint on metal that's already secure in its location, like
standing pipe, clamping is not much of an issue. But on free-moving
plates or objects, and during fabrication projects, you'll need to spend
considerable time on set-up and/or fit-up before you even think of
striking an arc. In the photo above top left are three common types of
clamps used for metal work. Each will quickly affix sheet metal or plates
to a flat surface. General purpose C-clamps and bar clamps can also be
used in fixturing and fit-ups.
To the right at the top is a photo of a corner clamp. Here, a welder would
insert two adjoining bars or tubing to be welded together at a right angle
(e.g. for a frame). After a secure tack weld is made, the frame sides can
be removed from the clamp and welded.
The last photo above features a "four-in-one" multi-purpose pipe clamp
that retails for about $70. Clamps are long lasting tools, so you can
usually find good ones for less money at flea markets and garage sales.
--Adjustable Wrench
If you're working with compressed gases, you'll need a wrench to loosen
the nut that fastens the regulator between hoses and tanks. The tanks
may require a chain or other restraint (as shown above), so make sure
it's secure before attaching or detaching regulators.
Using a soapstone marker with a combination square
Measurements and Marking
Like wood construction, metalwork requires the use of rulers, squares,
levels and other measuring devices. For most student projects and
small jobs, a tape measure, combination square and calipers should
suffice.
Marking cut or joint lines metal can be challenge. Unlike wood, the
surface of metal is slippery, dark and smudgy. So welders and
metalsmiths use three types of markers:
Sharpie - or other water-resistant ink marker
soapstone - a whitish rock mineral
scriber - a steel tool that etches a sharp line
Vice
As a beginning welder, you can probably get by without a hefty cast iron
vice, but the advantages of having one are vast. With a work piece
secure in its grips, you can tack, weld, grind, file, paint and cut metal
without having to worry about any collateral damage to your welding
table or the vice itself. Another use of the vice is to straighten out
crooked sheet metal, although an anvil, hammer and English press are
best suited for this.
As you can see from the photo above, the base of a vice has convenient
slots that fasten to a sturdy work table using three bolts. (You may need
to use your oxy torch or plasma gun to gouge the holes in the table, if
your hand drill isn't up to the task. Then follow up with a pneumatic die
grinder or deburring tool, or a round hand file to smooth around the
openings. The adjustment crank (near the man's hand in the photo)
allows you to rotate the vice around to different positions.
--Safety Gear
In addition to a welding helmet, gloves and leather clothing, a welder
needs ear plugs and safety glasses. Depending on the job, a few other
implements are usually furnished by an employer, such as a hard hat
attachment to the welding helmet, a dust mask or ventilation device.
Extra thermal protection for situations involving high temperatures may
also be provided.
In a home shop, don't forget to have a fire extinguisher mounted within
easy reach. And be sure you know how to use it.
Tools & Welding Tables
Education is learning to use the tools humanity has found indispensable.
-Josiah Royce
Introduction
To know what tools and equipment are needed for a welding job, you need to understand the steps
required in the fabrication process:
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
Get or make a fabrication sketch or drawing.
Develop a well thought out welding procedure.
Gather all necessary welding equipment including measuring tools.
Gather all materials to be welded.
Make patterns, jigs, templates and fixtures, if needed.
Put together a cut list.
Lay out and cut materials.
Clean metal areas to be welded and make the edge preparations.
Position and clamp materials prior to welding.
Tack weld assemblies, check dimensions, setup and squareness.
Place the final welds and assemble the fabrication.
Paint the fabrication promptly to avoid rust formation.
Section I – Hand Tools
Measuring Tools
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Framing, carpenter’s, cabinetmaker’s and combination squares – Use the largest square that fits the
work. The combination square is convenient for the layout of 45º corner cuts and short, parallel lines.
Grind the outside corners off the carpenter’s and cabinetmaker’s squares to allow them to fit snugly
into work corners that have a fillet weld in place. See Figure 4-1 (A, B, C & D).
Builder’s and torpedo levels – Use the larger builder’s level whenever possible because it is more
accurate and measures over a longer span. Use the torpedo level wherever the builder’s level won’t
fit. See Figure 4-1 (E & F).
Figure 4-1. Common measuring and leveling tools for welders: (A) framing square, (B) carpenter’s square, (C)
cabinet maker’s square, (D) combination square, (E) torpedo level and (F) builder’s level.
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Compass and dividers – For scribing circles or stepping off a series of equal intervals.
Steel measuring tape – The most convenient sizes are the 16' and 24' tapes. These are also useful
for measuring curved surfaces.
Precision steel rules – Available in lengths from 6–72", these steel rules are for measuring along or
drawing a straight line.
Metal Marking Tools
The following items will mark metal:
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Snapped chalk lines, which use a mason’s string.
Welder’s chalk, also called soapstone.
Ball point metal marking pen.
Single center-punch mark or a line of center-punch marks.
Silver Streak welder’s pencil.
Felt-tip pen, such as a Sharpie.
Aerosol spray paint.
Scribed lines either on bare metal or on layout fluid.
Use welder’s soapstone for marking rough dimensions, bend lines, and to indicate cutting lines that
need to hold up under cutting torch heat. A line of center-punch marks can be more accurate and will
also withstand torch heat. For very accurate layout lines, spray paint the metal in the area of the
layout lines and use a scriber to scratch through the paint to make the lines. Alternatively,
machinist’s layout fluid—available in red or blue—can be used to make the scribed lines visible.
Although these lines will not hold up under torch heat, they can be essential to laying out non-torch
cutting lines. Felt-tip pens can be used in place of layout fluid to darken the metal to better show
scribed lines. Do not use scribe marks to designate bend or fold lines since they are stress raisers
and the part will eventually fail along the scribed line.
Welding Hand Tools
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Chipping hammer to remove welding slag, particularly for SMAW.
Files for bringing an oversized part down to exact dimensions, removing a hazardous razor edge or
burr, and smoothing the ends of wire-feed electrodes before feeding them through the torch liner.
Ball pein hammer and cold chisel to break tack welds.
Pliers, such as Channel Locks, for moving hot metal safely.
Wire cutters to trim electrode wire (GMAW and FCAW only).
Hack saws for slow, but accurate metal cutting.
Wire brush for cleaning welds. See all these tools in Figure 4-2.
Figure 4-2. Welding hand tools.
Clamps
Figure 4-3 shows general purpose clamps for welding. These clamps include:
:
(A) bar clamp,
(B) pipe clamp, (C & D) C-clamps, (E) KantTwist clamp and (F) come-along.
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C-clamps.
Bar clamps and pipe clamps are used to clamp across long spans.
Come-alongs, also called cable pullers, are used to pull large, long or stiff parts into position. These
are particularly good on structural steel for pulling frames into square.
KantTwist-type heavy-duty clamps. Figure 4-4 shows how to tighten KantTwist clamps using a
wrench. Pulling them up without a wrench does not take full advantage of their clamping power.
Figure 4-4. Method to tighten KantTwist clamps.
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Bessey welding clamps are heavier and stronger than general-purpose welding clamps, and more
expensive, but usually worth it. See Figure 4-5.
Figure 4-5. Several designs of Bessey heavy-duty welding clamps.
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Corner-clamping fixtures, such as the Bessy corner clamp in Figure 4-6, make getting accurate rightangle joints easier. Although these clamps are most often used sequentially to weld up corner joints,
sometimes four or more are positioned on a rigid base to form a fixture for production work. These
clamps have aluminum bases and copper-plated screws so welding spatter does not stick to them.
Figure 4-6. Bessey corner clamps hold work firmly in position for welding at right angles.
Arc Welding Processes and Equipment
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ME Mechanical Team
Last updated: Sep 26, 2016
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Arc Welding Processes
In arc welding process, an electric arc between an electrode and a workpiece or between two electrodes
is utilized to weld base metals. The basic principle of arc welding is shown in below Fig. 1. However,
the basic elements involved in arc welding process are shown in the below Fig. 2. Most of these
processes use some shielding gas while others use coatings or fluxes to prevent the weld pool from the
surrounding atmosphere.
Figure 1: Principle of arc welding
The ten various types of arc welding processes are mentioned below:
1. Carbon Arc Welding
2. Shielded Metal Arc Welding (SMAW)
3. Flux Cored Arc Welding (FCAW)
4. Gas Tungsten Arc Welding (GTAW)
5. Gas Metal Arc Welding
6. Plasma Arc Welding
7. Atomic Hydrogen Welding
8. Electroslag Welding (ESW)
9. Stud Arc Welding
10. Electrogas Weldin (EGW)
Arc Welding Equipment
Arc welding equipment, setup, related tools, and accessories are shown in Fig. 2.
(1) Switch box. (2) Secondary terminals.
scale.
gloves.
(3) Welding machine.
(5) Current regulating hand wheel.
(8) Protective glasses strap.
for cable protection.
brush.
(9) Electrode holder.
(12) Welding cable.
(15) Earth clamp.
(6) Leather apron.
(4) Current reading
(7) Asbestos hand
(10) Hand shield.
(13) Chipping hammer.
(16) Welding table (metallic).
(11) Channel
(14) Wire
(17) Job.
Figure 2: Arc welding process setup
However, some common tools of arc welding are shown below in Fig. 3. Few of the important
components of arc welding setup are described as under.
1. Arc welding power source
Both direct current (DC) and alternating current (AC) are used for electric arc welding process, each
having its particular applications. DC welding supply is usually obtained from generators driven by
electric motor or if no electricity is available by internal combustion engines. For AC welding supply,
transformers are predominantly used for almost all arc welding where mains electricity supply is
available. They have to step down the usual supply voltage (200-400 volts) to the normally open circuit
welding voltage (50-90 volts). The following factors influence the selection of a power source:
1. Type of electrodes to be used and metals to be welded
2. Available power source (AC or DC)
3. Required output
4. Duty cycle
5. Initial costs and running costs
6. Efficiency
7. Available floor space area and
8. Versatility of equipment
2. Welding cables
Welding cables are required for conduction of current from the power source through the electrode
holder, the arc, the workpiece and back to the welding power source. These are insulated copper or
aluminium cables.
3. Electrode holder
Electrode holder is used for holding the electrode manually and conducting current to it. These are
usually matched to the size of the lead, which in turn matched to the amperage output of the arc welder.
Electrode holders are available in sizes that range from 150 to 500 Amps.
Figure 3: Arc welding tools and accessories
4. Welding Electrodes
An electrode is a piece of wire or a rod of a metal or alloy, with or without coatings. An arc is set up
between electrode and workpiece. Welding electrodes are classified into the following types
1. Consumable Electrodes
i.
Bare Electrodes
ii.
Coated Electrodes
2. Non-consumable Electrodes
i.
Carbon or Graphite Electrodes
ii.
Tungsten Electrodes
Consumable electrodes are made up of different metals and their alloys. The end of this electrode starts
melting when the arc is struck between the electrode and workpiece. Thus consumable electrode itself
acts as a filler metal. Bare electrodes consist of a metal or alloy wire without any flux coating on them.
Coated electrodes have flux coating which starts melting as soon as an electric arc is struck. This
coating on melting performs many functions like prevention of joint from atmospheric contamination,
arc stabilizers etc.
Non-consumable electrodes are made up of high melting point materials like carbon, pure tungsten or
alloy tungsten etc. These electrodes do not melt away during welding. But practically, the electrode
length goes on decreasing with the passage of time, because of oxidation and vaporization of the
electrode material during welding. The materials of non-consumable electrodes are usually copper
coated carbon or graphite, pure tungsten, thoriated or zirconiated tungsten.
5. Chipping hammer
Chipping Hammer (shown in fig. 3.6) is used to remove the slag by striking.
6. Wire brush
Wire brush (shown in Fi. 3.7) is used to clean the surface to be weld.
7. Hand Screen
Hand screen is used for protection of eyes and supervision of weld bead.
8. Protective clothing
The operator wears the protective clothing such as apron to protect the body from the exposure of
direct heat to the body.
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