Here are a few tricks about plasma cutters and how to make the best purchase choices. Flat-Position Welding Increases Welding Speed : It’s common knowledge that welding in a horizontal position will be the easiest and fastest way to weld. A flat position is not as taxing to maintain and the welding puddle will stay in place. Take some time to evaluate each project before beginning in order to make sure the majority of welds can be completed in this position. If a job calls for vertical welding, see this article about vertical welding. Core Wire Feeder Increases TIG Welding Speed: For professional welders hoping to speed up TIG welding, a core wire feeder will add filler metal through an automated process. Watch this video on how it works. This enables welders to work with both hands and to maintain a constant flow of wire into the welding puddle. Ed Craig at the Frabricator writes about the wire feeder process first developed in Europe, saying it is “suitable for all-position welding on materials of any thickness, the process addresses traditional GTAW limitations and can enhance both manual and automated TIG weld quality and productivity.”
A MIG welder uses a continually feeding spool of thin filler wire as an electrode fed by a wire feed gun to form an electric arc between a wire and the work-piece metal. This heats the work-piece metal and the electrode, causing them to melt and join together to create the weld. Mig welding can be either Gas or Gasless and each have benefits. Gasless welding is far more portable as there’s no gas bottle to carry around, saves cost on having to buy gas bottles and regulators, is easier on positional welds and can penetrate deeper than Gas MIG although the welding wire for a gasless MIG is more expensive than a gasless MIG. Gas MIG welding produces much cleaner welds with no slag or spatter, is slightly better on thinner metals and the welding wire is cheaper than gasless MIG wire.
Delivery of parts to the welding station in an organized and logical fashion is also a way to reduce welding costs. For example, one company was manufacturing concrete mixing drums. In the fabrication process, the company produced 10 parts for one section, then went on to make 10 parts of another drum section, etc. As pieces came off the line, they were put onto the floor of the shop. When it was time to weld, the operator had to hunt for the pieces needed and sort through them. When the outside welding expert pointed out the amount of time being wasted in this process, the company started to batch each one on a cart. In this way, the pieces needed to weld one drum were stored together and could easily be moved to the welding area. This type of scenario is also true for companies that may outsource parts to a vendor. Though it may cost more to have parts delivered in batches, it may save more in time than having to organize and search through parts to be able to get to the welding stage. How many times each piece is handled in the shop may be an eye-opener to reducing wasted time. To measure such an intangible as this, operators are asked to put a soapstone mark on the piece each time it is touched – some companies are surprised to find out how many times a part is picked up, transported and laid down in the manufacturing process. In the case of one company, moving the welding shop closer to the heat treatment station eliminated four extra times that the part was handled. Basically, handling a part as few times as possible and creating a more efficient production line or work cell will reduce overall costs. Looking for the best Welding Fume Extraction? We recommend Welding Supplies Direct & associated company TWS Direct Ltd is an online distributor of a wide variety of welding supplies, welding equipment and welding machine. We supply plasma cutters, MIG, TIG, ARC welding machines and support consumables to the UK, Europe and North America.
TIG welding filler wire and Mig welding wire from a spool are essentially the same composition except that mig welding wire often contains more silicon and that can actually be a good thing for TIG welding steel. Don’t hesitate to use steel or stainless steel mig wire if you run out of TIG welding filler metal. If its too small, double it up and twist it up in a cordless drill. Standard Tig wire for welding mild steel is E70S2 It seems like the standard mig welding wire off the shelf these days is almost always E70S6. The 2 and the 6 indicate the addition of silicon and deoxidizers in the wire. Stainless tig and mig wire is most often E308L unless you ask for something else.
MIG welders advices: how to become a more skilled welder and how to choose the top welding equipment. TIG Torch angle should only be around 10 degrees or less: Ideally, torch angle should only be around 10 degrees or less. Too much torch angle will deflect the heat and melt the rod before you ever get it into the puddle. This causes the rod to ball up and blob into the puddle. That’s bad. You don’t want that. You want to slip the filler rod into the puddle so that you can get a consistent bead. There are exceptions to this…like when you are using a lay wire technique and leaning the torch back while you walk the cup. But if you are dipping the rod in the puddle, too much torch angle usually is not a good thing.
Contact tips can have a significant impact on MIG welding performance since this consumable is responsible for transferring the welding current to the wire as it passes through the bore, creating the arc. The position of the contact tip within the nozzle, referred to as the contact tip recess, is just as important. The correct contact recess position can reduce excessive spatter, porosity, insufficient penetration, and burn-through or warping on thinner materials. While the ideal contact tip recess position varies according to the application, a general rule of thumb is that as the current increases, the recess should also increase.
Make sure everything is ‘squeaky’ clean. TIG welding is not tolerant of any contaminants. Be sure to clean your base metal with a good degreaser, BEFORE you scrub it with a dedicated wire brush. Do not use the same brush on different kinds of metal. Wipe the filler rod down with degreaser, too. Get comfortable. Whenever possible, I like to be seated when I’m welding. Even in situations where sitting isn’t possible, any little adjustments to my stance or body position that make me more comfortable will have a noticeable effect on the weld. Source: https://www.weldingsuppliesdirect.co.uk/.