Posts Tagged ‘weld’

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TIG Welding 101

July 9, 2009

It is like a rising superstar in this day in which we live. The art of TIG welding has been around for some time but is becoming an ever popular application for welding.

It is drawing upon the curious side of someone already interested in the field of welding. TIG welding is a very unique form of welding. When you begin to use the left and right hand simultaneously in any process there is more stress involved to the welder and this technique requires more agility than does the more common practices of welding.

When you embark upon a career in TIG welding there are normally pre-requisites that have already been achieved by the time you arrive in the TIG domain. Stick welding is normally a foundation before a welder steps into the world of TIG.

Rarely does the TIG process stand alone. There are places that you find the MIG and TIG process alone but those areas do not entail the vast majority. Some places you may see just the TIG would be the Aero-Space Industry, lightweight bicycles, hospital equipment, dairy production, etc. For the most part, the TIG process will find you in the Petro-Chemical Industry, Chemical Refining, and the Fossil Fuel Industry. Power plants, refineries, chemical plants and the likes is actually the place that the biggest money is made as well as the pipeline; which used to be downhill stick only and reserved for the welder with the big head and the rig truck he worshipped as a god.

Things have come a long was needless to say. The welder in general used to have an upper-hand in his craft but not so any more. Most people in these industries look at the welder in general as a cry baby and whiner who is always looking for the ideal conditions in which to perform his operation.

But! The TIG welder is someone that is still in high demand and carries some prestige connected to his ability to be ambidextrous. The TIG hand can weld stick, MIG, TIG usually whether it is carbon or alloy metals.

The further the welder can move into the realm of the exotic, the more in demand he becomes. The more certifications he can obtain, the more in need he will find himself (or herself). The bad part about the area of TIG welding that we are talking about at this stage is the different environments that go with this type of welding. The already mentioned places that usually call for this type of welding are not the most pleasant places to work.

These type of environments eventually take a toll upon the body of the individual. It is not easy to sustain good optimal health in fume and particulate saturated environments. Toxins and poisons are present. Elevated structures with scaffolding enclosed by fire retardant blanket. Noise levels that can and most of the time due require hearing protection.

Come to think about it, the bike factory is becoming more appealing all the the time. LOL!

Actually, a good TIG hand that is respected in his trade can call the shots. He sizes up the fit on pipe and if it isn’t correct he shoots it down, because once he starts welding on it he has taken the responsibility in saying I can make it happen. A good TIG welder can make a bad fitter look good. Or take a bad fit and turn the fabricators heartburn into Rolaids to the rescue.

An older man that has become well versed in his trade is widely respected by his peers when he becomes known as the TIG daddy, the man, the khaki daddy, etc. There are up and coming young men that are always following in the footsteps of the well accomplished mentor TIG welder.

TIG comes with a few essential items that must be recognized. Clean clothes every morning with starched shirts and a nice skull cap. A bandanna in the back pocket. A bandanna around the neck like a businessman would wear a tie to the office. Fairly new looking gloves that are not your run of the mill leather.

TIG welding requires sensitivity in the fingertips and hands. Most of the time a good TIG hand has cash in his wallet and is on top of his game. The problem we see with that in our economy is that he has to travel a bit more than he would like to keep that going. The benefit of that is that he will always have a job because of his skills. You see the TIG welder is selling his skill.

He doesn’t produce a product so to speak. His arsenal of tools contain his favorite hood or two, small hand tools that are used to accent his skill. Sharp tungsten stored in his tool bag or bucket. Files, die grinders, small wrenches, flapper wheels, emory cloth, filler rod, a coffee thermos (very important), extra gloves and lenses if needed, and possibly some small fit up wedges or flat head screwdrivers.

In our next article we will look at the actual components of his equipment for a further breakdown in lesson TIG 102. Until then, thanks for your time and take care!

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Ideas on: How to choose the correct Stick Rod

July 19, 2008

Hello and welcome back to another article in our Stick Rod Series. Today we will focus on Flux Coated Rods_How to Choose The Right Rod. Because of the technologies of mankind today there are many rods that are suitable for different purposes. There are also many companies that make the same rods or rods that are very similar. 

For most of the basic stick rod needs there are not to many overwhelming choices or categories to deal with. Don’t get me wrong there are multiple choices but most of those rods will not be needed in the average welders life. 

Even if you weld in a specialty field. You will probably stay within a select area of welding materials to do the repetition of your daily duties. 

The most common metal you will ever weld on and to will be carbon steel. Carbon steel also known as iron, is the most basic metal and probably the most common. It is an element from natural deposits that has been smelted or refined into structural or pipe steel. 

When welding to steel or iron the most common rods will be carbon based rods. 

6010,7010, maybe 8010. These ten series rods are fast freeze rods that are basically the same in their characteristics and function. They go up in strength from 60,000 to 80,OOOlbs. in tensile strength. They are all position rods. These are AC rods which is the most common current today in America. There are some DC rods that are available like 6011 and 6013. These rods are good for fusing basic iron components together. Farm equipment, structural steel, pipe welding, shipyards, shop work, etc. 

The complimentary rods that can go with these in similar applications would be 7018, 8018, all the way up to 11018. 70,000 to 110,OOOlb. tensile strength. These rods are not fast freeze AC rods they produce less sparks and spatter while welding. They are slower moving rods that produce a more consistent puddle and have more ductility than fast freeze rods. Fast freeze rods tend to be more brittle in composition. The difference is mainly in the flux. 

Ductility is the ability of metal to be drawn out into wire. This means that in this process the metal doesn’t break or fatigue. There is a resilience in the metal to maintain its core characteristics. 

There are special rods for cast iron welding. Metals that are cast have a crystalline core that is tough to weld on. Radnor makes an excellent rod for this called 5044. Of course there are many others. The cast iron process is actually best welded with brass. Brass is very difficult to make nice. Some welding is good looking but brass is not. 

Shipyards use brass on propellers and props. Brazing is a popular method of welding with brass. There are rods that are more like a tig filler metal that have a flux coating around them that are used with a torch burning process and not electricity. 

Inkonel is an iron/nickel composite for cast iron. Cast iron welding requires massive heat applied to the metals and a slow cool down period to keep the weld from cracking. 

Old time lawn furniture like your grandmother had is usually cast iron. Old stoves, engine blocks (some not all), bailey blocks in the floor of a boiler or furnace, wrought iron needs a high nickel rod. 

Well that’s all we have time for today. Next time we will talk about more on the Stick Rod Series. If you would like a f.r.ee ebook I wrote click here.


To your success!! Michael D. Treadway.