ITI TECHNICAL GURU(आईटीआई तकनीकी गुरु): May 2017

Tuesday, 30 May 2017

mig welding process

MIG welding


Advantage Fabricated Metals performs a number of welding processes. The two most common welding processes we use include TIG, an acronym for Tungsten Inert Gas welding and MIG, an acronym for Metal Inert Gas welding. TIG is also referred to as GTAW (Gas Tungsten Arc Welding) and Heliarc®. MIG also is referred to as GMAW (Gas Metal Arc Welding). We also provide oxy-acetylene welding.

The "Metal" in Gas Metal Arc Welding refers to the wire that is used to start the arc. It is shielded by inert gas and the feeding wire also acts as the filler rod. MIG is fairly easy to learn and use as it is a semi-automatic welding process.
Characteristics of the MIG welding process

MIG:

    Uses a consumable wire electrode during the welding process that is fed from a spool,
    Provides a uniform weld bead,
    Produces a slag-free weld bead,
    Uses a shielding gas, usually – argon, argon - 1 to 5% oxygen, argon - 3 to 25% CO2 and a combination argon/helium gas,
    Is considered a semi-automatic welding process,
    Allows welding in all positions,
    Requires less operator skill than TIG welding,
    Allows long welds to be made without starts or stops,
    Needs little cleanup.

The illustration that follows provides a look at a typical MIG welding process showing an arc that is formed between the wire electrode and the workpiece. During the MIG welding process, the electrode melts within the arc and becomes deposited as filler material. The shielding gas that is used prevents atmospheric contamination from atmospheric contamination and protects the weld during solidification. The shielding gas also assists with stabilizing the arc which provides a smooth transfer of metal from the weld wire to the molten weld pool.

MIG welding process - illustration

Versatility is the major benefit of the MIG welding process. It is capable of joining most types of metals and it can be performed in most positions, even though flat horizontal is most optimum.

The most common welds are illustrated below. They include the:

  •     lap joint
  •     butt joint
  •     T-joint, and the
  •     edge joint

MIG weld joints - illustration

MIG is used to weld many materials, and different gases are used to form the arc depending on the materials to be welded together. An argon CO2 blend is normally used to weld mild steel, aluminum, titanium, and alloy metals. Helium is used to weld mild steel and titanium in high speed process and also copper and stainless steel. Carbon dioxide is most often used to weld carbon and low alloy steels. Magnesium and cast iron are other metals commonly welded used the MIG process.

View an overview of our welding services and any of the metal forming processes offered by Advantage Fabricated Metals by clicking on the links above.

For more information about Advantage Fabricated Metals and the metal forming, metal fabricating, and welding services we provide, please fill out our contact form or call us at 1-815-323-1310.
Related metal fabricating services, tips and facts:
MIG Welding

Gas Metal Arc Welding (GMAW) is frequently referred to as MIG welding.  MIG welding is a commonly used high deposition rate welding process.  Wire is continuously fed from a spool.  MIG welding is therefore referred to as a semiautomatic welding process.
   

Mig Weld
MIG Welding Benefits

     All position capability
     Higher deposition rates than SMAW
     Less operator skill required
     Long welds can be made without starts and stops
     Minimal post weld cleaning is required

MIG Welding Shielding Gas

The shielding gas, forms the arc plasma, stabilizes the arc on the metal being welded, shields the arc and molten weld pool, and allows smooth transfer of metal from the weld wire to the molten weld pool.  There are three primary metal transfer modes:

     Spray transfer (MP3 Audio)
     Globular transfer (MP3 Audio)
     Short circuiting transfer (MP3 Audio)

The primary shielding gasses used are:

     Argon
     Argon - 1 to 5% Oxygen
     Argon - 3 to 25% CO2
     Argon/Helium

CO2 is also used in its pure form in some MIG welding processes.  However, in some applications the presence of CO2 in the shielding gas may adversely affect the mechanical properties of the weld.

   

Mig weld of Pipe

Close up of Mig Weld
Common MIG Welding Concerns

We can help optimize your MIG welding process variables. Evaluate your current welding parameters and techniques.  Help eliminate common welding problems and discontinuities such as those listed below:
Weld Discontinuities

     Undercutting
     Excessive melt-through
     Incomplete fusion
     Incomplete joint penetration
     Porosity
     Weld metal cracks
     Heat affected zone cracks

   

MIG Welding Problems

     Heavily oxidized weld deposit
     Irregular wire feed
     Burnback
     Porosity
     Unstable arc
     Difficult arc starting

Monday, 29 May 2017

mechanical engineering: welding and its classification

Welding:

Welding is a process of joining two metal pieces by the application of heat. Welding is the least expensive process and widely used now a days in fabrication. Welding joints different metals with the help of a number of processes in which heat is supplied either electrically or by mean of a gas torch. Different welding processes are used in the manufacturing of Auto mobiles bodies, structural work, tanks, and general machine repair work. In the industries , welding is used in refineries and pipe line fabrication. It may be called a secondary manufacturing process.
Classification of welding processes:
There are about 35 different welding and brazing process and several soldering methods, in use by the industry today. There are various ways of classifying the welding for example, they may be classified on the basis of source of heat(flames ,arc etc.)
In general various welding processes are classified as follows.
1: Gas Welding
(a): Air Acetylene
(b): Oxy  Acetylene
(c): Oxy Hydrogen Welding
2: Arc Welding
(a): Carbon Arc welding
(b); Plasma Arc welding
(c): Shield Metal Arc Welding
(d): T.I.G. ( Tungsten Inert Gas Welding)
(e): M.I.G. ( Metal Inert Gas Welding)
3: Resistance Welding:
(a): Spot welding
(b): Seam welding
(c): Projection welding
(d): Resistance Butt welding
(e): Flash Butt welding
4: Solid State Welding:
(a): Cold welding
(b): Diffusion welding
(c): Forge welding
(d): Fabrication welding
(e): Hot pressure welding
(f): Roll welding
5: Thermo Chemical Welding
(a): Thermit welding
(b): Atomic welding
6:  Radiant Energy Welding
(a): Electric Beam Welding
(b): Laser Beam Welding
Welding Joints
Different types of welding joints are classified as Butt, Lap , Corner, Tee and edge joints which are shown in figure



Welding Types


Types of welding, welding tips and equipment.
Welding Types Home

Welcome to welding types, this site about welding is to provide information and welding tips for all of the different types of welding, welding equipment and machines, including mig, tig and arc, resistance welding, solid state welding, micro welds, plasma cutting, and learning how to weld,

The main Types of welding used in industry and by home engineers are commonly referred to as Mig welding, Arc welding, Gas welding and Tig welding.mig welding
GMAW or Gas Metal Arc Welding

More commonly called MIG welding this welding type is the most widely used and perhaps the most easily mastered type of welding for industry and home use. The GMAW process is suitable for fusing mild steel, stainless-steel as well as aluminium.tig welding
GTAW or Tungsten Inert Gas

TIG welding is comparable to oxy acetylene gas welding and needs a lot more expertise from the operator. Employed for carrying out high-quality work when a superior standard of finish is needed without making use of excessive clean up by sanding or grinding.arc welding
Arc Welding or SMAW

Generally known as stick or arc welding. Arc welding is the most basic of all welding types, is easy to master in a home welding situation.
Stick welding can be used for manufacturing, construction and repairs, very much well suited for heavy metal size 4 millimetres upwards. Thinner sheet metals and alloys are usually more suited to the mig welding types. gas weldingGas or Oxy
 Acetylene Welding And Cutting

Not used as widely for general welding of mild steel. Consists of mixing oxygen and acetylene gas to greate a flame capable of melting steels. Mostly used today for maintenance work and gas metal cutting. Also common for brazing softer metals such as copper and bronze. Can also be used for welding delicate aluminium parts such as refrigeration pipes.

Gas Cutting equipment for metal construction and maintenance. The most accessible of thermal cutting gear is by qxy-acetylene gas cutting and plasma cutting machines. Other methods include the use of a thermal cutting electrode for use with the arc welder machine
Welders Protective Gear.

Any form of welding offers risks to the operator’s health. To minimise these risks we must use welding equipment and protective gear as welding helmets, gloves, leather jackets and in some cases breathing apparatus.
Welding Machines.

Looking to buy welding machine or welder inverter but aren’t sure on what suits your requirements. What to look for in a welder machine for home and workshop use, Mig , Tig and Arc welders.
How to Weld

Learning how to weld a skill that most will be abl;e to master. From Basic MIG welding to the more advanced TIG welding there are procedures that need to be learned and practiced to become a proficient welder.

Monday, 15 May 2017

Welding Machines - Welding Types

Welding Types

Types of welding, welding tips and equipment.
Welding Types Home
Welcome to welding types, this site about welding is to provide information and welding tips for all of the different types of welding, welding equipment and machines, including mig, tig and arc, resistance welding, solid state welding, micro welds, plasma cutting, and learning how to weld,
The main Types of welding used in industry and by home engineers are commonly referred to as Mig welding, Arc welding, Gas welding and Tig welding.
GMAW or Gas Metal Arc Welding
More commonly called MIG welding this welding type is the most widely used and perhaps the most easily mastered type of welding for industry and home use. The GMAW process is suitable for fusing mild steel, stainless-steel as well as aluminium.

 

GTAW or Tungsten Inert Gas

TIG welding is comparable to oxy acetylene gas welding and needs a lot more expertise from the operator. Employed for carrying out high-quality work when a superior standard of finish is needed without making use of excessive clean up by sanding or grinding.

 

Arc Welding or SMAW

Generally known as stick or arc welding. Arc welding is the most basic of all welding types, is easy to master in a home welding situation.
Stick welding can be used for manufacturing, construction and repairs, very much well suited for heavy metal size 4 millimetres upwards. Thinner sheet metals and alloys are usually more suited to the mig welding types.

 

Gas or Oxy Acetylene Welding And Cutting

Not used as widely for general welding of mild steel. Consists of mixing oxygen and acetylene gas to greate a flame capable of melting steels. Mostly used today for maintenance work and gas metal cutting. Also common for brazing softer metals such as copper and bronze. Can also be used for welding delicate aluminium parts such as refrigeration pipes.
Gas Cutting equipment for metal construction and maintenance. The most accessible of thermal cutting gear is by qxy-acetylene gas cutting and plasma cutting machines. Other methods include the use of a thermal cutting electrode for use with the arc welder machine
Welders Protective Gear.
Any form of welding offers risks to the operator’s health. To minimise these risks we must use welding equipment and protective gear as welding helmets, gloves, leather jackets and in some cases breathing apparatus.

 

Welding Machines.

Looking to buy welding machine or welder inverter but aren’t sure on what suits your requirements. What to look for in a welder machine for home and workshop use, Mig , Tig and Arc welders.



How to Weld

Learning how to weld a skill that most will be abl;e to master. From Basic MIG welding to the more advanced TIG welding there are procedures that need to be learned and practiced to become a proficient welder.
Categories
·    Admin Updates
·    Arc Welding
·    How To Weld
·    Mig Welding
·    Tig Welding
·    Types Of Welding
·    Welders
·    Welding Equipment
·    Welding Helmets
Welding Resources
·    AWS
·    Mig-Welding UK
·    WeldingWeb
·    Welding Types
·    Types of welding, welding tips and equipment.
·    Welding Machines
·    Types Of Welding Machines
·    Welder machines come in all shapes and sizes from the small home workshop welder to industrial welding machines used for car manufacture and specialized industries.

·    Mig welding machines

  • ·    – Regarded as the most versatile and the most common welding machine in home workshops and industry. Can be used for welding several different metals including mild steel, stainless steel and aluminium. Top models include Miller, Lincoln and Hobart.
  • ·    Tig welding machines
  • ·    – More specialized than mig welders tig machines are used for precision work and can weld more types of metal than any other process. Metals suitable to tig weld are stainless steel, mild steel, aluminum,copper, bronze, brass, gold, magnesium, chromoly, and nickel alloys.
·    Tig welding gives pure clean welds without splatter, sparks and smoke fumes. Ideal for welding metal artwork, aluminum cycle and motorcycle frames plus clean stainless welding for applications such as food processing equipment.
  • ·    Arc Welders. Basic weld machine that have been around for many years. Can be purchased for very little money these days and in the right curcumstances can be very useful. Ideal for repair work where a mig welder is not suited to such as on site and field work where portability is needed and also where welding gasses can be blown away due to wind.
  • ·    Spot Welding Machines
  • ·    -Spot Welding is a common resistance welding technique utilized to join 2 to 4 overlapping steel sheets that are anywhere up to 3 mm thick each. In many applications using just 2 overlapping metallic sheets, the sheet thickness could be as much as 6 millimeters. A pair of electrodes are concurrently utilized to secure the metal sheets together and move current throughout the sheets.
Some great benefits of the technique consist of effective power use, restricted workpiece deformation, higher manufacturing rates, simple automation, with no necessary filler materials. Spot welding is employed instead of more expensive mechanized fastening, for example riveting and screwing, and when disassembly for maintenance is not needed. Whilst weld strength at each weld spot is significant, the fact that the weld spots don’t form a continuing seam ensures that the general sturdiness is usually considerably less than with welding techniques, making the procedure suited to only specific applications. It’s utilized broadly within the motor vehicle industry where cars can have several thousand spot welds.
  • ·    Plastic Welding machines
  • ·    Plastic welding is one of the most innovative and different kinds of processes. It is specially designed for welding plastic materials, which are otherwise difficult to weld using conventional welding processes. For how to weld plastic parts, the films are fused and pressure is applied against them. The technique of plastic welding is diverse in nature, and has many variants with high number of applications for industrial use.
Types of Welding Machines
This entry was posted on March 28, 2015 by admin.
Welding machines and joining machines encompass those devices that are used for numerous joining processes. These processes include:
  • ·    arc welding (MIG, TIG, stick, submerged arc)
  • ·    resistance welding
  • ·    laser welding
  • ·    electron beam welding
  • ·    stud welding
  • ·    orbital welding
  • ·    wave soldering
  • ·    hot dip brazing
  • ·    torch brazing
  • ·    induction brazing
  • ·    ultrasonic
  • ·    friction welding
The various types of welding machines and joining machines include the complete devices as well as their power sources, monitors, and controllers used for welding , brazing and soldering.
Complete Welding Machine Systems:
Welding machines and joining machines can be supplied as complete systems, which come with a welding power source, and a weld monitor or controller.
A complete welding machine or joining machine system is comprised of a complete welding, surfacing, or cutting machine, equipment, or system. Also included are a power source, torch or gun, cables, feeders, positioners, robots, or other required components.
A power source for a welding machine or a joining machine provides a TIG gun, MIG gun, electrode holder, laser, electron beam gun or other welding unit with the required output power to melt material.
Welding monitors or controllers for welding machines are instruments that sense welding quality (nugget size or weld integrity) or output power supply variations. Also, welder controllers are used to adjust welding parameters to compensate for variations in weld quality or output power.
Among the arc or resistance-welding types that apply to welding machines and joining machines are:
  • ·    Flux Cored Arc Welding (FCAW)
  • ·    Gas Metal Arc Welding (GMAW)
  • ·    Multi-process
  • ·    Orbital / Tube Arc Welding
  • ·    Plasma arc welding
  • ·    Flash welding
  • ·    Projection welding
  • ·    Resistance seam welding
  • ·    Spot welding
  • ·    Shielded Metal Arc Welding (SMAW)
  • ·    stud arc welding
  • ·    Submerged arc welding (SAW)
  • ·    Gas Tungsten Arc Welding (GTAW)
Frictional or other fusion welding types that apply to weld machines and joining machines include:
  • ·    Electron beam welding
  • ·    friction welding
  • ·    Hot plate welding
  • ·    plastic welding
  • ·    Laser welding
  • ·    Oxyfuel welding
  • ·    Thermite or exothermic welding
  • ·    ultrasonic or linear friction welding
You must consider output power specifications when looking into entire welding machine systems and/or joining machine systems, as well as the power systems for these machines. You need to be aware of the duty cycle, or the percentage of time the welding unit can remain on in a ten-minute period before powering off to cool and prevent damage to components.
Check the output power capability specifications, which include AC output, DC output, AC/DC selectable output, and high frequency. Find out what the output current range of the welding or joining machine system is. (This is the designed current range of the welding unit or the current range monitored or controlled.) Also look at the output voltage range, which is the designed voltage range of the welding unit or the voltage range monitored or controlled.
Engine-driven generators, machine duty or corrosion resistance, multi-operator, and water-cooled are features that are common to welding and joining machines.
Go to http://www.millerwelds.com for a wide selection of welding machines.
What are the Different Types of Welding Machines Used in Different Industries?


Oliverwen Joe Wen


usa
Welding Machine is equipment, which is used to weld or joint two metals or alloys together using another metal component as filler. Usually structure-less metals and alloys are joint using types of welding machines to give them desired shape and make them sturdier than they would be if it were a single piece.
These machines are available in different sizes as per their utility. A large size machine would be used in a factory and a handy machine is available for domestic purpose. Types of machines that are available in the market vary from Arc welding machine, types of welding machines, Plasma Cutting machine, Resistance welding machine, Solid State Welding machine and less known types are Induction and Thyristorised welding machines.
Among all the types of welding machines, Arc type machines are the most efficient and effective. According to the type of material used to weld, they are broadly classified into three categories.
Common most is the Manual Metal Arc mechanism. The tool looks like a stick, which performs the function of a main electrode, and it is covered by a flux that prevents it from oxidization. With the help of electricity, the electrode melts itself continuously for types of welding machines. This equipment is mostly used for small tasks. This kind of machine is usually used in construction industry, maintenance and repair of small metals, cutting and making holes in steel products and rebuilding fixtures.
Second form is a Metal Inert Gas mechanism which is a large bobbin like formation. It is a single piece of equipment that includes a mix of argon or helium gas or both used along with the heated electrode to camouflage the metal from rusting. This makes the task easy and quicker. Metal Inert Gas equipments are mainly used in shipbuilding, power plants, aerospace equipments, automobile industry, bridge constructions and refineries.
The third kind is Tungsten Inert Gas, which has a single electrode, and the protective material is provided by another resource. The electrode does not thaw out as it has an additional tool to give it protection. This type of mechanisms is used in large factories where it is impossible to use other type of welding machines. Principally, Tungsten Inert Gas machines are used in power plants, construction industry, aerospace industry and manufacturing industry for more robust and specialized welding.
Apart from these, other type of welding machines that are available in the market are:
·    Carbon Arc, which is used for welding alloy steel and water jet cutting.
·    Orbital or Tube Arc is used in casting, shipbuilding, automotive industry etc.
·    Plasma Arc is used for welding of surgical instruments, food industry, dairy industry etc.
·    Stud Arc is mostly utilised in fabrication and machining.
·    Submerged Arc is chiefly used in industrial welding and pipe welding.
Any industry usually uses a combination of any of the above machines as per requirement. Welding machines are easy to use but is a complex piece of machinery and hence should be operated under expert guidance.