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Old 01-23-2011, 04:33 PM
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Crazy Horse Crazy Horse is offline
Join Date: Feb 2009
Location: USA
Posts: 1,150
Thumbs up Welcome To The Welding & Metalworking Forum

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Welding & Metalworking, share and ask questions here about welding & metalworking, and or all things welding & metalworking related.

Welding Processes
Discussions of all welding and allied processes including but not limited to; stick, mig, tig, oxy/fuel welding and brazing.

General Welding Information
This section is meant as a reference area for general welding data, safety information, etc.

Show off you projects and pictures of them and general discussions of fabrication techniques, knowledge and equipment.

Gases & Consumables
Discuss the many variety's of consumables, gases, and MIG/TIG Welding Flowmeter Regulators.

For discussion of turning, milling, drilling, tapping, precision grinding, etc. Related equipment, techniques and practices.

Metallurgy and Materials
General discussion on the metals and materials we use in our projects.

Shop Building
Discuss building a shop, electrical needs, compressed air systems, shop layout, shop equipment, and other relevant needs.

CNC Machines, Submerged Arc, Automated Systems, and other cutting methods
This is the place to discuss alternative cutting methods such as cutting with CNC Tables, Oxy-Fuel, and other cutting methods.

Plasma Cutting
General tips, ideas, tricks, and basic introduction on how to use Plasma Cutters.

Welding (Auto-Darkening) Helmets and Gear
Discuss Welding Helmets and other gear.

Welder Manufacturers
Discussions about Welders & Welding products from any manufacturer, such as.

Everlast Welders & Equipment

Harbor Freight Welders & Equipment

Hobart Welders & Equipment

Lincoln Welders & Equipment

Longevity Welders & Equipment

Miller Welders & Equipment

What Are the 3 Types of Welding?

1. Stick, MIG and TIG welding are 3 of the most common types of welding.

Stick, MIG and TIG welding are 3 of the most common types of welding.
Welding is a process in which two pieces of metal are joined together using heat and electricity. A filler material is used to form a pool of molten metal that cools to become a strong joint between the pieces. Welding is used in many different industries, including construction, shipbuilding, aeronautics and electronics. There are many different welding processes, but the most common are stick welding, metal inert gas (MIG) welding and tungsten inert gas (TIG) welding.

Stick Welding

2. Stick welding, also known as Shielded Metal Arc Welding (SMAW) is one of the easiest and most common types of welding. The electrode, or "stick" that gives this type of welding its name, is covered with a metal coating that melts and forms a gas shield as the heat is applied, adding slag, deoxidizers and alloy to the welded metal. Slag is created when globules of molten metal solidify on the surface of the weld--these must be chipped off. Stick welding equipment is simple to use and inexpensive. The electrode provides its own flux, eliminating the need for additional supplies. Stick welding can be used in all positions (welding done flat, horizontal, vertical and overhead) and has a lower sensitivity to drafts than gas-shielded welding. However, these welds have a very rough appearance.

MIG (Metal Inert Gas) Welding

3. Metal inert gas, or MIG, welding uses a spool of solid-steel wire that is fed to the work area from a machine through a contact tip in the MIG "gun." The contact tip is electrically charged when the trigger of the gun is pulled, which melts the wire for the weld puddle. MIG is usually used in indoor welding where drafts will not displace the gas shielding. However, it can be used in the field with wind blocks, such as plastic sheets. MIG welding can be used on stainless steel, mild steel and aluminum. It can be used to weld in all positions. You do not have to chip off slag build-up, and it is relatively easy to learn. Disadvantages include having to use a cumbersome tank of shielding gas and the cost of consumables like tips and nozzles.

TIG (Tungsten Inert Gas) Welding

4. Tungsten inert gas, or TIG, welding can be used on a wider variety of materials, provides very high quality welds and does not produce toxic smoke or fumes. The argon gas used in this process protects the weld from contamination, so no slag is produced. Welds can be done in all positions. All of these benefits make TIG welding an ideal choice for confined spaces. TIG welding requires more skill and experience to produce a good weld, however. The torch must be held at the right angle, the weld-pool must be kept uniform and the right filler must be used.

What's the difference between MIG, TIG, and ARC Welders

Arc welders produce a variable current with the use of a transformer and use a welding rod in order to create the weld. There is a flux around the welding rod used to prevent reaction of the metal with atmospheric gases such as oxygen and nitrogen. However, this flux creates slag that must always be removed.

MIG welding, also known as Metal Inert Gas welding, is by far the easiest to learn. The MIG electrode is consumable and a MIG Shield or a flux core in the metal wire removes atmospheric gases from the welding area. MIG units are better for beginners as they create cleaner welds, however they do not have the capacity of welding thick metals in the way that arc welders do.

TIG welding, also known as Tungsten Inert Gas welding, is one of the more difficult styles of welding to master. The electrode in made of tungsten, and non-consumable, unlike the MIG electrode. However, the TIG and MIG welders both have a flux core in the metal wire which removes oxygen, nitrogen and other potentially reactive gases from the welding area.

When choosing an arc welder, one needs to take into consideration their level of skill and the usage of the welder. For beginners, a MIG welder is probably best as it is the easiest to use or for those wishing to perform auto work due to their clean welds. However, over time a MIG welder, with its consumable electrode, becomes very expensive. For those who wish to weld thicker metals an arc welder should be that of choice. TIG welders are good for more advanced users who need the thicker metal welding ability of the arc welder. When choosing a TIG arc welder, remember that ferrous metals require DC current and non-ferrous require AC current in TIG welders. Choose the welder which is not necessarily more popular, but which best fits your skill level, budget and the use you will make of it.

Shielding gases are inert or semi-inert gases that are commonly used in several welding processes, most notably gas metal arc welding and gas tungsten arc welding (GMAW and GTAW, more popularly known as MIG and TIG, respectively). Their purpose is to protect the weld area from atmospheric gases, such as oxygen, nitrogen, carbon dioxide, and water vapor. Depending on the materials being welded, these atmospheric gases can reduce the quality of the weld or make the welding process more difficult to use. Other arc welding processes use other methods of protecting the weld from the atmosphere as well shielded metal arc welding, for example, uses an electrode covered in a flux that produces carbon dioxide when consumed, a semi-inert gas that is an acceptable shielding gas for welding steel.

Improper choice of a welding gas can lead to a porous and weak weld, or to excessive spatter; the latter, while not affecting the weld itself, causes loss of productivity due to the manpower needed to remove the scattered drops.

What Is the Difference Between TIG Welding & MIG Welding?

Tungsten inert gas (TIG) and metal inert gas (MIG) are two types of arc welding processes. There are a few similarities between the two methods and many differences.

1. TIG welding uses a tungsten electrode that is not consumed during the welding process. MIG welding uses a metal electrode that doubles as filler material for the weld and is consumed during welding.

Shielding Gas
2. TIG welding primarily uses argon as a shielding gas, with helium occasionally used. Argon is also the primary shielding gas used in MIG welding, but argon mixtures and carbon dioxide are often used for different applications.

Filler Material
3. TIG welding requires a separate filler material in rod or wire format because the electrode is not consumed. MIG welding delivers the filler material via the electrode.

Work Piece Materials
4. TIG welding can be applied to just about any metal, from steel to aluminum and exotic alloys. MIG welding was developed for nonferrous metals, but can be applied to steel.

5. TIG welding is considered to be more difficult than MIG welding because tighter tolerances have to be maintained between the electrode, the filler rod and the work piece.

Oxy-Fuel Welding and Cutting aka Brazing
Oxy-Fuel is one of the oldest welding processes, though in recent years it has become less popular in industrial applications. However, it is still widely used for welding high end Bicycles pipes and tubes, as well as repair work. It is also frequently well-suited, and favored, for fabricating some types of metal-based artwork.

Brief history of Brazing Bicycles
French engineers Edmond Fouch and Charles Picard became the first to develop an oxygen-acetylene welding set-up in 1903. Pure oxygen, instead of air (20% oxygen/80% nitrogen), is used to increase the flame temperature to allow localized melting of the workpiece material (e.g. steel) in a room environment. A common propane/air flame burns at about 2,000 C (3,630 F), a propane/oxygen flame burns at about 2,500 C (4,530 F), and an acetylene/oxygen flame burns at about 3,500 C (6,330 F).

Custom Fabrication & Metalworking

Bicycle Frame Jigs & Custom Metal Jigs For Building Gas tanks

To Be Continued.

Last edited by Crazy Horse; 01-25-2013 at 03:28 PM. Reason: typos
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