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 |  موضوع: كتاب Welding For Dummies الجمعة 08 نوفمبر 2024, 10:46 pm | |
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أخواني في الله
أحضرت لكم كتاب
Welding For Dummies
by Steven Robert Farnsworth
و المحتوى كما يلي :
Contents at a Glance
Introduction 1
Part I: Understanding Welding Basics . 7
Chapter 1: Diving Into the World of Welding .9
Chapter 2: Considering Commonly Welded Metals .19
Chapter 3: Setting Your Sights on Welding Safety .33
Chapter 4: Setting Up Your Welding Shop 53
Part II: Welding on a Budget: Stick and Tig Welding 71
Chapter 5: Getting on the Stick: Understanding Stick Welding 73
Chapter 6: Getting to Work with Stick Welding .85
Chapter 7: To Tig or Not To Tig: Understanding Tig Welding .105
Chapter 8: Trying Out Tig Welding 119
Part III: Discovering Mig Welding . 133
Chapter 9: Understanding the ABCs of Mig Welding .135
Chapter 10: Practicing Mig Welding 147
Part IV: Getting Fancy: Plasma Cutting,
Oxyfuel Cutting, and Other Processes 157
Chapter 11: Examining Plasma and Oxyfuel Cutting .159
Chapter 12: Ready, Set, Cut! Trying Out Plasma Arc Cutting
and Oxyfuel Cutting 173
Chapter 13: Exploring Special Weld Processes 187
Chapter 14: Exploring Pipe Welding 205
Chapter 15: Working with Cast Iron 217
Part V: Putting Welding into Action
with Projects and Repairs . 229
Chapter 16: Two Welding Projects to Boost Your Welding Shop 231
Chapter 17: Constructing a Campfire Grill 249
Chapter 18: Fixin’ to Fix Things: Analyzing and Planning .257Part VI: The Part of Tens 273
Chapter 19: Ten Tools Every Welder Wants 275
Chapter 20: (Not Quite) Ten Advantages of Being a Certified Welder 285
Chapter 21: (Almost) Ten Welding Defects 291
Chapter 22: Ten Signs You’re Welding Correctly 301
Chapter 23: Ten Maintenance Tips for Your Welding Equipment and Shop .307
Glossary 319
Index 343Table of Contents
Introduction . 1
About This Book 1
Conventions Used in This Book .2
What You’re Not To Read .2
Foolish Assumptions .3
How This Book Is Organized 3
Part I: Understanding Welding Basics .3
Part II: Welding on a Budget: Exploring Stick and Tig Welding 4
Part III: Discovering Mig Welding .4
Part IV: Getting Fancy: Plasma Cutting, Oxyfuel Cutting,
and Special Processes .4
Part V: Putting Welding into Action with Projects and Repairs .4
Part VI: The Part of Tens .5
Icons Used in This Book .5
Where to Go from Here .5
Part I: Understanding Welding Basics . 7
Chapter 1: Diving Into the World of Welding . . . . . . . . . . . . . . . . . . . . . .9
If You Can’t Beat ’Em, Join ’Em: Understanding
Why Welding Matters 10
Fabricating metal products 10
Repairing metal pieces or products 10
Getting Familiar with Metals 12
Steel .13
Stainless steel .13
Aluminum 14
Taking the Time to Understand Welding Safety 14
Exploring Welding Methods .15
Stick welding .15
Mig welding .16
Tig welding 17
Other welding methods .17
Looking at the Future of Welding 18xii Welding For Dummies
Chapter 2: Considering Commonly Welded Metals . . . . . . . . . . . . . . . .19
Steeling Yourself for Using Steel 20
Getting a handle on forms of steel .20
Knowing when steel is appropriate .21
Preparing steel for welding .23
Exploring steel welding methods .26
Going with Stainless Steel .27
Understanding the differences between steel
and stainless steel 27
Deciding when to use stainless steel .27
Looking at stainless steel welding methods .28
Working with Aluminum .29
Perusing the properties of aluminum .29
Eyeing aluminum welding techniques .30
Considering Other Metals .30
Chapter 3: Setting Your Sights on Welding Safety. . . . . . . . . . . . . . . . .33
Gearing Up to Protect Yourself 34
Choosing eye protection .34
Keeping the right fi re extinguisher on hand .36
Wearing protective clothing .38
Watching health hazards: Using a respirator
and Material Safety Data Sheets .39
Observing Basic Safety Rules .40
Keeping your work space clean .41
Checking for leaks 42
Getting the ventilation right .42
Storing fl ammable liquids and gases .43
Knowing your surroundings .44
Protecting yourself from electric shock .45
Shielding yourself from burns 46
Maintaining your equipment 47
Being Prepared for Injuries and Accidents 48
Equipping your first-aid kit .48
Knowing how to handle injuries 49
Chapter 4: Setting Up Your Welding Shop. . . . . . . . . . . . . . . . . . . . . . . .53
Choosing a Location 53
Deciding how much space you need .54
Contemplating indoor versus outdoor .55
Equipping Your Welding Shop .56
Making sure you have the basic hand tools .58
Choosing a welding table 61
Selecting your welding machine 62
Considering a few accessories for your welding shop 67Table of Contents xiii
Part II: Welding on a Budget: Stick and Tig Welding 71
Chapter 5: Getting on the Stick: Understanding Stick Welding . . . . .73
Looking at the Pros and Cons of Stick Welding .73
Understanding the Factors That Infl uence Stick Welding 75
Getting Familiar with Stick Welding Equipment 76
Discovering the differences among stick welding machines .76
Setting up your stick welding machine .79
Nailing down the basics of stick welding’s electrodes .80
Choosing tools and supplies every stick welder needs 81
Chapter 6: Getting to Work with Stick Welding. . . . . . . . . . . . . . . . . . .85
Preparing to Stick Weld 86
Setting up your work area .86
Understanding stick welding electrodes 87
Setting the Machine .90
Choosing polarity .91
Setting the amperage .91
Preparing to weld .92
Striking and Maintaining an Arc 93
Assume the Position: Stick Welding in All Positions .95
Welding on a flat surface .96
Going vertical .97
Exploring horizontal welding .101
Reaching overhead 102
Chapter 7: To Tig or Not To Tig: Understanding Tig Welding . . . . . .105
Taking a Closer Look at Tig Welding Components .106
Considering the Advantages and Disadvantages of Tig Welding 106
Brushing Up on Tig Welding Basics 108
Showing your metal: Looking at a few metals for tig welding 108
Taking steps to ensure quality welds 109
Stocking the Shop: Examining Tig Welding Equipment 110
Considering fully equipped tig machines .111
Thinking about tig torches .112
Selecting and managing shielding gas .112
Controlling current and amperage 115
Selecting filler metal 116
Exploring tungsten electrodes .117
Chapter 8: Trying Out Tig Welding . . . . . . . . . . . . . . . . . . . . . . . . . . . . .119
Getting Your Welding Setup Tig-ether 119
Taking care of tungsten electrode details 120
Making sure your shielding gas is set up correctly .122
Figuring out your tig filler rods 123xiv Welding For Dummies
Matching Materials and Settings .124
Getting a Handle on Using Your Tig Torch 125
Choosing an electrical current and striking the arc 125
Get a grip: Holding your tig torch correctly .127
Giving Tig Welding a Try 127
Tackling the first weld .128
Trying a butt joint 129
Welding a lap joint .130
Making a T joint 131
Part III: Discovering Mig Welding . 133
Chapter 9: Understanding the ABCs of Mig Welding . . . . . . . . . . . . .135
Understanding How Mig Welding Works 136
Considering Mig Welding’s Advantages and Limitations .138
Bringing out the Big Guns (And Other Mig Welding Equipment) 139
Mig welding machines .140
Mig welding guns .140
Electrode wire feeders 141
Sifting through Shielding Gases for Mig Welding 142
Taking a Look at Electrode Wire 143
Adjusting Mig Equipment to Suit your Mig Welding Project 145
Chapter 10: Practicing Mig Welding . . . . . . . . . . . . . . . . . . . . . . . . . . .147
Preparing to Mig Weld 147
Getting the equipment ready .148
Setting the wire feed speed and voltage .150
Trying Out Mig Welding 151
Making vertical mig welds 154
Joining pieces of sheet metal .155
Watching Out for Common Mig Welding Defects 155
Part IV: Getting Fancy: Plasma Cutting,
Oxyfuel Cutting, and Other Processes . 157
Chapter 11: Examining Plasma and Oxyfuel Cutting . . . . . . . . . . . . . .159
Understanding Plasma Arc Cutting .159
Identifying some good materials for plasma cutting .160
Taking a look at plasma cutting’s advantages
and disadvantages .161
Perusing and Preparing Plasma Arc Cutting Equipment 162
Getting a handle on plasma cutting equipment .162
Setting the equipment up properly .164Table of Contents xv
Exploring Oxyfuel Cutting Basics 165
Considering what you can (and can’t) cut with oxyfuel .165
Looking at the pros and cons of oxyfuel cutting .166
Checking Out and Setting Up Oxyfuel Cutting Equipment .166
Examining oxyfuel cutting equipment .167
Deciding among different gas cylinder sizes 169
Setting up oxyfuel cutting equipment .170
Chapter 12: Ready, Set, Cut! Trying Out Plasma Arc Cutting
and Oxyfuel Cutting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .173
Exploring Plasma Arc Cutting 173
Slicing a straight line .174
Cutting a circle .176
Creating a bevel .177
Practicing Oxyfuel Cutting 178
Lighting the torch 179
Making a straight cut .181
Cutting out a circle 183
Taking on a beveled edge .184
Chapter 13: Exploring Special Weld Processes. . . . . . . . . . . . . . . . . .187
Working through the Basics of Welding with Gas .187
Taking a gander at gas cylinders .188
Looking at more gas welding equipment 189
Getting to work with gas welding 191
Discovering Brazing (Braze Welding) .195
Keeping a few brazing rules in mind .195
Giving brazing a try .195
Finding Out about Fusion Welding 197
Soldering On: Exploring Soldering 199
Following the rules of soldering .200
Understanding the two types of soldering .202
Trying the soldering process .202
Chapter 14: Exploring Pipe Welding. . . . . . . . . . . . . . . . . . . . . . . . . . . .205
Delving into the Different Kinds of Pipe .206
Getting Down to Welding Steel Pipes 206
Getting set up and preparing the pipe 207
Making the tacks 209
Welding the pipes 210
Trying some other angles .212
Peeking at a Few More Types of Pipe Welding Joints .214
Keeping an Eye Out for Common Pipe Welding Defects .214xvi Welding For Dummies
Chapter 15: Working with Cast Iron . . . . . . . . . . . . . . . . . . . . . . . . . . . .217
Casting Light on the Three Most Common Types of Cast Iron .217
Gray cast iron .218
Malleable cast iron 218
Nodular cast iron .219
Getting the (Cast) Iron in the Fire: Welding Gray Cast Iron .221
Stick welding cast iron 221
Oxyfuel welding cast iron .224
Mig welding cast iron 227
Part V: Putting Welding into Action
with Projects and Repairs . 229
Chapter 16: Two Welding Projects to Boost Your Welding Shop . . .231
Creating a Torch Cart 231
Gathering the materials 233
Acquiring the right steel pieces .233
Measuring and cutting pieces 234
Making the welds .236
Adding the wheels .240
Checking your welds .241
Picking out your paint .242
Fabricating Your Own Portable Welding Table .242
Rounding up your tools 243
Picking out the parts .243
Assembling the pieces .244
Ensuring smooth edges .247
Choosing your paint 248
Putting on the wheels 248
Chapter 17: Constructing a Campfi re Grill . . . . . . . . . . . . . . . . . . . . . . .249
Fabricating a Campfire Grill .249
Getting your tools in order .249
Obtaining the proper steel pieces .250
Cutting the steel pieces to length 251
Welding the grill .253
Picking out your paint .256
Seasoning the cooking surface .256
Chapter 18: Fixin’ to Fix Things: Analyzing and Planning. . . . . . . . . .257
Determining Whether Something Is Fixable .258
Planning a Repair Strategy .259
Identifying the metal and what it means for the repair 260
Deciding which welding process to use for your repair .264
Making and following your plan .265Table of Contents xvii
Getting Ready to Make Repair Welds 266
Preparing your repair piece and work area .266
Gathering your equipment and tools 267
Selecting fi ller rods and electrodes .268
Considering Cracks .269
Part VI: The Part of Tens . 273
Chapter 19: Ten Tools Every Welder Wants . . . . . . . . . . . . . . . . . . . . .275
41⁄2-Inch Grinder 276
Hacksaw 276
Air Compressor 277
3⁄8-Inch Electric Drill 277
Wrench Set .278
Steel Sawhorses .278
Cutoff Saw .280
Bench Grinder 281
Bottle Jack 282
Toolbox .282
Chapter 20: (Not Quite) Ten Advantages of
Being a Certifi ed Welder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .285
More Job Opportunities 286
Better Pay .286
More Chances for Advancement .287
Certifi cation that Travels with You .288
Ability to Join a National Organization .288
Qualifi cation in Specifi c Areas of Welding 289
Increased Confi dence in Your Welding Skills 289
Listing in the American Welding Society Database .290
A Head Start on Additional Types of Welding Certification .290
Chapter 21: (Almost) Ten Welding Defects . . . . . . . . . . . . . . . . . . . . . .291
Incomplete Penetration 291
Incomplete Fusion .292
Undercutting 293
Slag Inclusions .294
Flux Inclusions .295
Porosity .296
Cracks .297
Warpage 298
Spatter .299xviii Welding For Dummies
Chapter 22: Ten Signs You’re Welding Correctly . . . . . . . . . . . . . . . . .301
The Weld Is Distributed Equally between Parts 301
The Slag or Shielding Material Doesn’t Stick to the Weld 302
No Holes or Irregularities on the Weld Surface .302
The Weld Is Tight .303
The Weld Is Leakproof 303
The Weld Has Full Penetration 304
The Weld Has No Undercutting .304
The Weld Has No Overlap 304
The Weld Meets Strength Requirements 305
You’re Safe and Healthy 305
Chapter 23: Ten Maintenance Tips for Your
Welding Equipment and Shop . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .307
Checking on Your Hand Tools .307
Taking Care of Power Tools .309
Doing Basic Housekeeping in the Shop 310
Protecting Your Welding Helmet .310
Seeing to Stick Welding Machine Maintenance .311
Working on Maintaining Your Mig Welding Machine .312
Tuning Up Your Tig Welding Machine 314
Taking Care of Your Oxyfuel Equipment 315
Keeping Your Air Compressor Working .316
Drill Press Maintenance 316
Glossary 319
Index . 343
Index
• A •
AC (alternating current), 91, 115, 319
acetone, 25, 319
acetylene, 319
acetylene cylinders, 188, 192
acid, in cleaning steel, 25
advancement, welding career, 287
air compressors
cost, 68
maintenance, 316
with plasma arc cutting, 174
uses, 277
air-acetylene, 319
air-arc cutting, 319
alcohol, in cleaning steel, 25
alloys, 261, 319
alternating current (AC), 91, 115, 319
aluminum. See also metals
alloy 3003, 30
alloys, 29
butt joint, 130
characteristics, 14
color test, 261
lap joint, 131
mig welding, 30
plasma arc cutting, 175–176
properties, 29–30
pure, 29, 30
repairs, 262
stick welding, 30
T joint, 132
tig welding, 30, 108, 125
welding process decision, 264
welding techniques, 30
working with, 29–30
American Welding Society (AWS)
certifications. See also certified welder
advantages, 286–290
defined, 285
as national organization, 288
pursuing, 285
skill demonstration, 286
in specifi c welding areas, 289
as traveling certification, 288
ammeters, 319
amperage
adjusting after starting, 92
defined, 90
high, as defect cause, 294
low, as defect cause, 292, 293, 295
setting, 90, 91–92, 97
stick welding, 75, 90, 91–92
tig welding, 115
angle grinders, 24
angle irons
campfi re grill project, 252
portable welding table project, 245, 247
torch cart project, 237–238
annealing, 187, 319
anvils, 68
arc blow, 81, 319
arc brazing, 319
arc cutting, 319
arc eye, 46
arc length, 75, 94, 319
arc striking, 93–95, 319
arc welding, 319
argon, 114, 142
austenite, 320
auto-darkening lenses, 35
autogenous welds, 116
AWS. See American Welding Society
certifications
• B •
back pass, 320
back up, 320
back welds, 320
backfi re, 180, 320
backhand welding, 320
backing rings, 208, 320
backing strips, 320344 Welding For Dummies
backstep, 320
back-up strips, 267
ball-peen hammers, 58, 60
base metal arc welding, 320
base metals
brazing, 195
defined, 320
postheating, 271
preheating, 271
in repairs, 265
bead welds, 320
beads, 320, 340
beanies, 38
bench grinders. See also grinders
abrasive wheels, 281
defined, 281
gloves and, 282
illustrated, 281
sharpening tools with, 282
bevels
defined, 321
oxyfuel cutting, 184–185
plasma arc cutting, 177–178
billets, 321
birds’ nest
defined, 312
fixing, 314
illustrated, 313
bleeding wound/injuries, 49
bonds, 321
bones, broken, 49
boots, 38
bottle jacks, 282, 309
box-end wrenches, 278
brass/bronze, color test, 261
brazing
base metals, 195
block, 321
butt joint, 195
cast iron, 226
corncob, 195, 197
defi ned, 17, 195, 321
dip, 324
fi ller rods, 195, 196
fi re bricks, 196
fl ux inclusions, 295
furnace, 327
induction, 329
lap joint, 195
passes, 196–197
process, 196–197
quenching metal, 196
resistance, 334
rules, 195
torches, 196, 197, 339
bridging, 321
buckling, 321
build-up sequence, 321
burns
chemical, 52
fi rst-degree, 50, 51
fl ash, 46, 326
heat, 50–51
risk, reducing, 47
second-degree, 50, 51
third-degree, 50, 51
butt joints. See also joints
brazing, 195
defi ned, 129, 321
fusion welding, 198
illustrated, 130
pipe welding, 207
tig welding process, 130
butt welds, 321
butter welds, 321
• C •
cable holders, 67
campfire grill
angle irons, 252
characteristics, 249
fabricating, 249–256
grill grate, premade, 251
grill grate assembly, 255
grill grate pieces, 253
illustrated, 250
paint, 256
partially constructed, 255
seasoning, 256
steel pieces, 250–251
tack welds, 253
tools for, 249–250
welding, 253–256
capillary action, 321
carbide precipitation, 321
carbon, in steel, 13
carbon dioxide, 142Index 345
carburizing fl ame, gas torch, 193, 322
cascade sequence, 322
case hardening, 322
cast iron
brazing, 226
carbon content, 217
color test, 260
defined, 217
fi ller rods, 225
graphite, 218
gray, 218
malleable, 218–219
mig welding, 227–228
nodular, 219
oxyfuel welding, 224–226
repair welds, 263
repairs on, 262
stick welding, 221–223
welding process decision, 264
working with, 217–228
C-clamps, 309
CDA (Copper Development Association), 262
center punches
in punching measurement lines, 236
in punching soapstone marks, 241
for repairs, 268
certified welder
advancement, 287
AWS database listing, 290
becoming, 285–286
job opportunities, 286
pay, 286–287
skill confidence, 289
in specifi c areas, 289
chamfering, 322
chemicals
burns, 52
cleaning steel with, 25
MSDS for, 25, 39
chipping, with stick welding, 75
chipping hammers, 58, 60, 308
chisels, 308
circles
oxyfuel cutting, 183–184
plasma arc cutting, 176–177
cleaning
steel, 23–25
with stick welding, 74, 75
work space, 41
clothing, protective, 38–39
coalescence, 322
cold cracks, 297
cold rolled steel, 21
color test, 260–261
combination squares, 83
concavity, 322
concurrent heating, 322
cone, 322
contaminated tungsten, 121–122
conventions, this book, 2
convexity, 323
copper
color test, 260
repairs, 262
tig welding, 108
uses, 31
welding process, 31
welding process decision, 264
Copper Development Association
(CDA), 262
corncob, 195, 197
corner joints, 323
corrosion
aluminum and, 14
defined, 323
stainless steel and, 13
steel and, 13
coveralls, 81
covered electrodes, 93
cracking the cylinders, 191
cracks. See also defects
cold, 297
crater, 297, 323
defined, 323
fixing, 271
hot, 297
illustrated, 270, 297
preventing, 271
reasons for, 270
in repair welding, 269–271
root, 334
stainless steel tig welds, 108
subsurface, 269
toe, 339
underbead, 340
crater cracks, 297, 323
creeper gauge, 315
creepers, 68346 Welding For Dummies
crescent wrenches, 58, 60
cup holders, 67
current, welding machines, 62, 115
cutoff saws, 280–281
• D •
DC (direct current), 91, 115, 324
defects
cracks, 269–271, 297
defined, 323
fl ux inclusions, 295–296
incomplete fusion, 156, 215, 292–293
incomplete penetration, 156, 215, 291–292
mig welding, 155–156
pipe welding, 214–215
porosity, 296
slag inclusions, 294–295
spatter, 15, 152, 208, 299
undercutting, 293–294
warpage, 298
deoxidizers, 109
deposited material, 323
deposition efficiency, 323
die, 324
die welding, 324
direct current (DC), 91, 115, 324
distortion, 236
downhill vertical mig welds, 154
drill presses, 69, 316–317
dross, 182
ductile iron. See nodular cast iron
ductile joints, 107
ductility, 12, 22, 324
duty cycle
defi ned, 62, 324
stick welding machines, 77
dye-penetrating test, 324
• E •
edge joints, 325
electric drills, 277–278
electric shock
safety, 45–46
victims, 50
electrical conductivity, 12, 22
electrical setback, 164
electrode holders, 82, 92, 325
electrode stubs
defined, 45
safety, 45
stick welding, 75
electrode wire. See also mig welding
carbon steel classifications, 144
cutting end of, 148
defined, 143
feed speed, 150–151
feeders, 141
liner, 148
purchasing, 144
selection, 151
size, 143
stub off, 153
electrodes
bare, 320
coated, 322
composite, 322
consumable, 322
defined, 325
dirty, 270
low hydrogen, 268–269
for repairs, 267
stick welding, 16, 74, 75, 80–81, 87–90
tig welding, 106, 112, 117, 120–122
equal pressure torches, 189
equipment. See also welding shops
air compressor, 68, 174, 277, 316
anvil, 68
ball-peen hammer, 58, 60
checking, 47
chipping hammer, 58, 60
creeper, 68
crescent wrench, 58, 60
drill press, 69
grinder, 69, 222, 247, 276, 281–282
hacksaw, 69, 276, 308
hand tools, 58–60
level, 58, 60
maintaining, 47–48
mig welding, 139–141
options, 57
pliers, 59Index 347
portable welding curtain, 69
soapstone/silver pencils, 59
steel square, 59, 60
stick welding, 76–83
straightedge, 59, 60
tape measure, 59, 267, 307
tig welding, 110–117
types of, 56–69
used, 58
vise, 69
vise grips, 59, 308
welding machine, 62–67
welding table, 61–62
wire brush, 60, 241, 308
etching, 325
eye injuries, 52
eye protection. See also gear, safety; safety
for bystanders, 35
welding helmet, 34–35
• F •
fabricating
campfi re grill, 249–256
defined, 10
metal products, 10
portable welding table, 242–248
torch cart, 231–242
fast fi ll electrodes, 268
fast freeze electrodes, 268
faying surface, 325
FCAW (fl ux core arc welding), 135, 326
ferrite, 325
ferrous metal, 261
fi eld welds, 325
fi ller metal, 116–117
filler rods
brazing, 195, 196
cast iron, 225
common, 123
defi ned, 116, 123, 190, 341
fusion welding, 197, 199
gas welding with, 190, 194, 269
illustrated, 116
nonferrous, 195
for repairs, 267, 269
RG-45, 269
RG-60, 269
RG-65, 269
tig welding with, 123
fi llet welds, 325
fi re bricks, 196
fire extinguishers. See also gear, safety;
safety
classes, 36, 37
cutting down on need for, 36
illustrated, 37
fi res, clothing, 50
fi rst-aid kits, 48–49
fl ame hardening/softening, 326
fl ammable gases, 44
fl ammable liquids, 43–44
fl ash burns, 46, 326
fl ash welding, 326
fl ashback, 180, 326
fl ashback arrestor, 315
fl at position, 326
fl at steel, 20, 21
flat surface
pipe welding on, 212–213
stick welding on, 96–97
fl ow meters, 113, 148
fl ow welding, 326
flux
correct, using, 201
defi ned, 93, 201, 202, 326
on electrodes, 93
illustrated, 202
in oxyfuel cast iron welding, 225
in soldering, 201, 202
soldering paste, 201, 202
fl ux core arc welding (FCAW), 135, 326
flux inclusions. See also defects
avoiding, 296
defined, 295
illustrated, 295
forehand method
defined, 326
fusion welding, 198
gas welding, 194
forge welding, 326
friction lighters, 190
fuel gases, 165
full feeders, 141348 Welding For Dummies
fusion, 327
fusion welding
butt joint, 198
defined, 197
fi ller rods, 197, 199
forehand method, 198
illustrated, 198
process, 198–199
torch, 198
welds, 199
with/without fi ller rods, 197
• G •
gas cylinders. See also oxyfuel cutting
acetylene, 188, 192
caps, 191
defi ned, 168, 323
gas welding, 188
large size, 170
leaking, 188
left-handed fittings, 188
moving, 188
oxyfuel cutting, 168, 169–170
oxygen, 188, 191
right-handed fittings, 188
selecting, 169–170
setting up, 170–171
shielding gas, 112
small size, 170
in torch cart, 232
valves, opening/closing, 191
gas metal arc welding (GMAW).
See mig welding
gas torches
acetylene valve, 194
for annealing, 187
body, 189
carburizing fl ame, 193, 322
equal pressure, 189
fuel valve, 192
lighting, 192–193
neutral fl ame, 192–193, 330
oxidizing fl ame, 193, 331
oxygen valve, 192
processes with, 187
setting up, 191–192
soldering with, 202
tips, 190
gas tungsten arc welding (GTAW). See tig
welding
gas welding
acetylene cylinder, 188
defi ned, 187, 327
equipment leaks, 42
fi ller rods, 190, 194, 269
fi nishing up, 194
forehand method, 194
friction lighter, 190
gas cylinders, 188, 191
gases, 187
goggles, 190
hoses, 190
oil/grease and, 190
oxyacetylene gas, 187
oxygen cylinder, 188
oxymapp, 187
position, 194
propane, 187
regulators, 190, 191
welds, 194
working with, 191–194
gases
fuel, 165
inert, 329
inhalation, 50
oxyacetylene, 187
oxymapp, 187
safety, 43–44
shielding (mig welding), 142–143
shielding (tig welding), 106, 109, 112–115,
122–123
gear, safety
eye protection, 34–35
fi re extinguishers, 36–37
Material Safety Data Sheets (MSDS) and, 39
protective clothing, 38–39
respirators, 39–40
generators, stick welding machine, 77, 78
globular transfer, 137, 327
gloves, 38, 82
GMAW (gas metal arc welding). See mig
welding
goggles, 190, 327
grapes, 210
gray cast iron
defined, 218
determination, 219Index 349
mig welding, 227–228
oxyfuel welding, 224–226
repairs on, 262
stick welding, 221–224
welding, 221–228
grill grate. See also campfire grill
assembly, 255
pieces, 253
premade, 251
seasoning, 256
welds, 254
grinders
bench, 281–282
cost of, 276
defined, 69
as dynamic tools, 276
41/2-inch, 276
for repairs, 267
sanding discs, 247
for V-shaped grooves, 222
grinding
pipe, 208
portable welding table, 247
torch cart welds, 241
tungsten electrodes, 121
groove welds, 327
grooves, 222, 292, 327
ground clamps, 82, 175, 176, 177
GTAW (gas tungsten arc welding). See tig
welding
guided bend test, 328
• H •
hacksaws, 69, 276, 308
hammers, 307
hand tools, 58–60
hardfacing, 263, 328
hardness, 22
hats, 38
heart attack, 50
heat burns, 50–51
heat sink, 328
heat sparks, 74
heat treating, 328
heating gate, 328
helium, 114, 142
helmets, welding
comfort, 35
lenses, 35
maintenance, 35, 310–311
need for, 34–35
in oxyfuel cutting, 179, 181
shade number, 35
stick welding, 81
high carbon steel, 20
high pressure pipes, 206
history, welding, 11
horizontal position, vertical pipe welding
in, 213
horizontal stick welding
defined, 101
fl at surface welding versus, 101
illustrated, 102
starting, 101
hoses
as leak source, 42
oxyacetylene, 179, 190
oxyfuel cutting, 168
hot cracks, 297
hot pass, 213
hot rolled steel, 21
hot short, 328
hydrogen, in welds, 270
• I •
icicles, 210
icons, this book, 5
impact test, 329
impregnated tape metal arc welding, 329
incomplete fusion. See also defects
causes, 293
defined, 292
illustrated, 293
mig welding, 156
pipe welding, 215
incomplete penetration. See also defects
causes, 292
defined, 291
illustrated, 292
mig welding, 156
pipe welding, 215
indoor welding, 55–56350 Welding For Dummies
induction welding, 329
injuries. See also safety
bleeding/wounds, 49
broken bones, 49
burns, 50–52
clothing fires, 50
electric shock, 50
eye, 52
fi rst-aid kits, 48–49
gas inhalation, 50
handling, 49–52
heart attack, 50
plume poisoning, 52
poisons, 50
stick welding, 87
inverters, 79
iron powder, 88
• J •
job opportunities, certifi ed welder, 286
joints
butt, 129, 130, 195, 198, 207
composite, 322
corner, 323
defined, 329
ductile, 107
edge, 325
lap, 130–131, 155, 195, 329
lateral, 214
repair, 265–266
root of, 335
socket, 214
T, 131–132, 214, 338
Y, 214
• K •
kerf, 235, 329
keyholes, 211, 213, 329
• L •
lap joints. See also joints
brazing, 195
defi ned, 130, 329
illustrated, 131
mig welding sheet metal, 155
tig welding process, 131
lateral T and Y joints, 214
layers, 212, 329
lead, color test, 261
leaks
checking for, 42
gas cylinders, 188
hose, 42
leather aprons, 39
leather jackets, 38
left-handed fi ttings, gas cylinders, 188
levels, 58, 60
lighting, for repairs, 267
liquidus, 329
local preheating, 330
low carbon (mild) steel, 20
low hydrogen electrodes, 268–269
low pressure pipes, 206
• M •
magnesium
tig welding, 108
uses, 31
welding process, 31
magnetism, 22
magnetism check, 261
maintenance tips
air compressor, 316
drill press, 316–317
hand tools, 307–309
mig welding machines, 312–314
oxyfuel equipment, 315
power tools, 309–310
shop housekeeping, 310
stick welding machine, 311–312
tig welding machines, 314–315
welding helmet, 310–311
malleable cast iron. See also cast iron
color test, 260
defined, 218
determination, 219
expense, 219
manifolds, 330Index 351
martensite, 330
mash seam welding, 330
Material Safety Data Sheets (MSDS)
for hazardous materials, 39
reading and understanding, 25
measurement
lines, center punching, 236
marks, drawing, 236
for torch cart project, 235–236
medium carbon steel, 20
medium pressure pipes, 206
melting point, 22, 330
melting range, 330
melting rate, 330
metal identification
aluminum, 262
cast iron, 262
with color chart, 260–261
copper, 262
kit, 261
magnetism check, 261
spark test, 220, 261
metallizing, 330
metals. See also specific metals
brazing, 195
characteristics, 12
ductility, 12, 22
electrical conductivity, 12, 22
ferrous, 261
fi ller, 116–117, 325
hardness, 22
hot, handling, 47
magnetism, 22
melting point, 22
nickel-based alloys, 31
nonferrous, 261, 331
for oxyfuel cutting, 165
parent, 293
for plasma arc cutting, 160
precious, 31
properties, 12, 22
quenching, 196
resistance to oxidation, 22
strength, 12, 22
for tig welding, 108–109
mig welding
advantages, 138–139
aluminum, 30
beads, 152, 153
benefits, 16
defects, 155–156
defi ned, 16, 135, 330
drawbacks, 16, 139
electrode wire feeders, 141
equipment, 139–141
equipment, readying, 148–149
feed speed, 145, 150–151
globular transfer, 137, 327
how it works, 16–17, 136–137
joining pieces of sheet metal, 155
penetration, 139
practicing, 147–156
preparing for, 147–151
pulse transfer, 137
robotic, 137
settings, experimenting with, 153–154
setup, 140
shielding gases, 142–143
short circuit transfer, 136, 150
spray arc transfer, 136–137, 150–151
stainless steel, 28, 150, 151
steel, 26
voltage, 145, 150–151
mig welding (cast iron)
on cracked cast iron, 227
illustrated, 228
mig gun, 228
process, 227–228
shielding gas, 227
weld backing, 227
mig welding guns
defined, 140–141
liner, 312, 313
moving, 152
mig welding machines
birds’ nest, 312, 313, 314
DC option, 140
defined, 65
design, 65
illustrated, 66
liner, 312, 313
maintenance, 312–314
power needs, 66
prices, 140
types of, 140
mixing chamber, 330352 Welding For Dummies
monel metal, color test, 261
MSDS. See Material Safety Data Sheets
multi-impulse welding, 330
• N •
neutral fl ame, gas torch, 192–193, 330
new welding machines, 63
nick break test, 330
nickel, color test, 261
nickel-based alloys, 31
nitriding, 330
nodular cast iron, 219
nonferrous fi ller rods, 195
nonferrous metal, 261, 331
normalizing, 331
nozzle tip, plasma cutting torch, 164
nugget, 331
• O •
Occupational Outlook Handbook
(OOH), 286
1G horizontal rolled open root pipe
weld, 212
open circuit voltage, 331
open-end wrenches, 278
organization, this book, 3–5
OSHA (Occupational Safety and Health
Administration) Web site, 43
outdoor welding, 56
output rating, stick welding machines, 77
overhead stick welding. See also stick welding
checking clothes and, 104
defi ned, 102, 331
illustrated, 103
process, 102–103
oxidizing fl ame, gas torch, 193, 331
oxyacetylene cutting/welding, 331
oxyacetylene gas, 187
oxy-arc cutting, 331
oxyfuel cutting
acetylene levels, 181
actions to avoid, 179
advantages, 166
beveled edges, 184–185
circles, 183–184
cutting tip, 169
defi ned, 18, 165
drawbacks, 166
dross, 182
equipment, 166–171
equipment setup, 170–171
friction lighter, 168
fuel gas, 165
gas cylinders, 168, 169–170
hoses, 168
ignition temperature, 165
metals, 165
oxygen levels, 181
practicing, 178–185
regulators, 168, 171
safety, 179
setup illustration, 167
straight lines, 181–182
welding helmet, 179, 181
oxyfuel cutting torches
backfi re, 180, 320
flashback, 180
illustrated, 168, 180
lighting, 179–180
maintenance, 315
operating, 180–181
shutting off, 181
oxyfuel welding (cast iron)
choice of, 224
fi ller rods, 225
flux, 225
items needed for, 224
process, 225–226
setup, 224
torch tip, 225
oxygen cutting, 331
oxygen cylinders, 188, 191
oxygen gouging, 331
oxy-hydrogen cutting/welding, 331–332
oxymapp, 187
oxy-natural gas cutting, 332
oxy-propane cutting, 332Index 353
• P •
paint
campfi re grill project, 256
portable welding table project, 248
for repairs, 268
torch cart project, 242
pants, 38
parent metal, 293
parts cart. See portable welding table
passes, 332
passive lenses, 35
pay, certifi ed welder, 286–287
peening, 332
penetration
defined, 304
full, 304
incomplete, 156, 215, 291–292
joint, 329
root, 335
percussive welding, 332
perlite, 332
piece failure. See also repairs
improving pieces to avoid, 265
mechanical failures causing, 265
reasons for, 258
pipe clamps, 209
pipe welding
backing rings, 208, 320
butt joint, 207
defects, 214–215
in fl at position, 212–213
grapes, 210
hot pass, 213
incomplete fusion, 215
incomplete joint penetration, 215
keyholes, 211, 213, 329
lateral T and Y joints, 214
movement in, 212
pipe types and, 205, 206
process, 210–212
root pass, 210–211, 213
side-to-side motion, 212
socket joints, 214
standards, 215
tacks, 209–210
undercutting, 211
vertical, in horizontal position, 213
pipes
aligning, 208
diameter, 209
grinding, 208
high pressure, 206
low pressure, 206
medium pressure, 206
Schedule 40, 207
setting up and preparing, 207–209
steel, 205
tacked, 213
wall thickness, 209
plasma arc cutters
illustrated, 163
regulatory assembly, 163
setting up, 164
torch connection, 163
types of, 174
plasma arc cutting
advantages, 161
air flow, 174
aluminum, 175–176
bevels, 177–178
characteristics, 160
circles, 176–177
defined, 159–160
diagram, 162
drawbacks, 161
equipment setup, 164
materials, 160
pilot arc, 175
preparing for, 162–164, 174
regulator, 174
straight lines, 174–176
plasma cutting torches
angling, 177–178
connection, 163
electrode tip, 164
nozzle, 193
nozzle insulator, 164
nozzle tip, 164
trigger, 175, 176, 177354 Welding For Dummies
plating, 332
platinum, welding, 31
pliers, 59, 308
plug welds, 332
plume poisoning, 52
poisons swallowed, 50
poke welding, 332
polarity
alternating current (AC), 91
defined, 333
direct current electrode negative
(DC- or DCEN), 91
direct current electrode positive
(DC+ or DCEP), 91
reverse, 334
setting, 90, 91
stick welding machines, 64, 76–77
straight, 337
porosity, 109, 296, 312
portable welding curtains, 69
portable welding table
angle irons, 245, 247
assembly, 244–247
castors, 244, 248
defined, 242
dimensions, 242
edges, smooth, 247
fabricating, 242–248
illustrated, 243
paint, 248
partial construction illustration, 246
parts, 243–244
parts illustration, 245
tack welds, 244
tools for, 243
washer welding position, 246
post-fl ow timers, 112
postheating, 333
power source
defined, 62
stick welding machine, 77–79
power tool maintenance, 309–310
precious metals, 31
pre-fl ow timers, 112
preheating, 333
pressure controlled welding, 333
pressure welding, 333
preweld intervals, 333
projection welding, 333
projects
campfi re grill, 249–256
portable welding table, 242–248
torch cart, 231–242
propane, gas welding and, 187
protective clothing, 38–39
puddles, 94, 333
pulsation welding, 334
pulse transfer, 137
push feeders, 141
push welding, 334
push-pull feeders, 141
• Q •
quenching, 196, 334
• R •
reaction stress, 334
reader assumptions, this book, 3
regulators
acetylene, 192, 194
defined, 334
gas welding, 190, 191
gauge, standing away from, 191
oxyfuel cutting, 168, 171
oxygen, 191
plasma arc cutting, 174
reinforced welds, 334
repairs. See also piece failure
aluminum, 262, 264
base metal condition, 265
base metal strength, 265
cast iron, 262, 264
compromise of other pieces and, 259
copper, 262, 264
cost versus new piece, 258–259
cracks and, 269–271
defined, 10
determination if fixable, 258–259
electrodes for, 267, 268–269
equipment and tools for, 267–268
equipment failure and, 258
fi ller rods for, 267, 269
fi rst step for, 258Index 355
hardfacing, 263
joints, 265–266
magnetism check, 261
metal color identifi cation chart for,
260–261
metal identification, 260–262
metal identifi cation kit and, 261
piece preparation, 266–267
plan, making/following, 265–266
skill level for, 265
spark test, 261
strategy, planning, 259–266
time for, 264
weld aesthetic, 264
weld preparation, 266–269
weld strength, 259
welding process decision, 264–265
as welding use, 10–11
work area preparation, 266–267
residual stress, 334
resistance butt welding, 334
resistance to oxidation, 22
resistance welding, 334
respirators
filters, 40
illustrated, 40
for repairs, 268
in stick welding, 82
types of, 39
right-handed fi ttings, gas cylinders, 188
robotic mig welding, 137
Rockwell hardness test, 334
root edge, 335
root face, 335
root pass, 210–211, 213, 335
• S •
safety. See also injuries
burns, 46–47, 50–52
cleaning, 25
electric shock, 45–46
equipment, 47–48
fi rst-aid kit, 48–49
fl ammable liquids/gases and, 43–44
gear, 34–40
importance of, 14
leaks, 42
oxyfuel cutting, 179
precautions, talking, 33
rules, 40–48
smells and sounds, 45
soldering, 201
surroundings, 44–45
tips, 41
ventilation, 42–43
work space, 41
sandblasting, 335
SAW (submerged arc welding), 338
sawhorses, steel, 278–280
scaling, 13
scarf, 335
scarfing, 335
Schedule 40 pipe, 207
scrap metal safety, 45
scratching method, stick welding, 95
screwdrivers, 308
seal welds, 335
seam welding, 335
selective block sequence, 335
series welding, 335
shade number, 35
sheet metal, mig welding on, 155
sheet separation, 335
shielded metal arc welding (SMAW). See
stick welding
shielding gases (mig welding)
argon/argon mixes, 142
carbon dioxide, 142
cast iron, 227
defined, 336
fl ow rate, 149
helium/helium mixes, 142
suggestions, 143
supply chamber installation, 148
shielding gases (tig welding)
argon, 114–115
cylinders, 112
defi ned, 106, 109, 336
fl ow meters, 113, 122
fl ow rate, 113
helium, 114
hook up, checking, 122
selecting and managing, 112–115
setting up, 122–123
solenoid and, 122–123356 Welding For Dummies
shirts, 38
shoes, 38
shop welds, 336
short circuit transfer, 136, 150
sidebars, this book, 2
single impulse welding, 336
slag
defined, 336
not sticking to weld, 302
in pipe welding, 208
in stick welding, 15
slag inclusions. See also defects
causes, 295
defi ned, 294, 336
illustrated, 295
slot welds, 336
slugging, 336
SMAW (shielded metal arc welding). See
stick welding
soapstones
circles, 176, 183
defi ned, 59, 96, 175
in oxyfuel cutting, 181, 183
in plasma arc cutting, 175, 176
as repair tool, 267
sharpening, 83
straight lines, 175, 181
in torch cart project, 241
uses, 59, 83
socket joints, 214
soft arc electrodes, 88
solder
applying, 203
cooling/hardening, 201
correct, using, 201
defined, 199
lead-free, 201, 202
rosin core, 201, 202
soldering
cleanup after, 203
defi ned, 18, 199, 336
drawbacks, 199, 200
flux, 201
fl ux inclusions, 295
with gas torch, 202, 203
heat application, 201
joint fit, 200
joint illustration, 200
joint strength, 199
materials, 201
materials illustration, 202
metal cleanliness, 200
process, 202–203
rules, 200–201
safety, 201
soft, 201
with soldering iron, 202, 203
torch, 201, 202
types, 202
uses, 199
solenoids, 122–123
spacer strips, 336
spall, 336
spark test, 220, 261
spats, 39
spatter
defi ned, 299, 336
illustrated, 152
minimizing, 299
in pipe welding, 208
in stick welding, 15
speed of travel
as incomplete penetration cause, 292
stick welding, 75, 95
weld size control with, 301
spool guns, 141
spot welding, 336–337
spray arc transfer, 136–137, 150–151, 337
stainless steel. See also metals
butt joint, 130
characteristics, 13
color test, 260
400 series, 27
lap joint, 131
mig welding, 28
steel versus, 27
stick welding, 28
T joint, 132
tig welding, 28, 108, 125
200 to 300 series, 27
use decision, 27–28
welding methods, 28
working with, 27–28Index 357
steel. See also metals
bars, 20
butt joint, 130
carbon, 13
characteristics, 13
cleaning, with chemicals, 25
cleaning, with mechanical methods, 23–25
cold rolled, 21
color test, 260
decision to use, 21–22
defined, 20
flat, 20
forms, 20–21
heat treating, 337
high carbon, 20
hot rolled, 21
information resource, 22
lap joint, 131
low carbon (mild), 20
medium carbon, 20
mig welding, 26, 150–151
preparing for welding, 23–25
stainless steel versus, 27
stick welding, 26
T joint, 132
tig welding, 26, 109, 124
weathered, 23
welding methods, 26
steel pieces
campfi re grill project, 250–251
portable welding table, 243–244
steel pieces, cutting, 251–253
torch cart project, 233–234
steel pipes. See also pipe welding
high pressure, 206
low pressure, 206
medium pressure, 206
with stick welding, 205, 206
welding, 206–215
steel sawhorses, 278–280
steel squares, 59, 60
stick welding
advantages, 74
aluminum, 30
arc length, 75, 94, 319
arcs, striking and maintaining, 93–95
combination square, 83
coveralls, 81
defi ned, 15, 337
drawbacks, 15–16, 74–75
electrode holder, 82, 92, 325
equipment, 76–83
factors influencing, 75–76
fl at surface, 96–97
gloves, 82
ground clamps, 82
horizontal, 101–102
how it works, 16
injuries, 87
overhead, 102–104
in pipe welding, 205, 206
popularity, 15, 64
positions, 95–104
preparation, 86–90, 92–93
respirator, 82
slowness, 75
soapstones, 83
speed of travel, 75, 95
stainless steel, 28
steel, 26
success factors, 94–95
tig welding machines for, 111
tools and supplies, 81–83
vertical, 97–100
welding cables, 83
welding helmet, 81
work area setup, 86–87
working with, 85–104
stick welding (cast iron)
components for, 222
cracked cast iron, 221, 223
drill/drill bit, 222
electrodes, 222
grinder, 222
illustrated, 224
oxyacetylene torch, 222
process, 223–224
temperature indicating crayon, 223
stick welding electrodes
amperage, setting, 90, 91–92
angle, 75, 94
arc blow, 81358 Welding For Dummies
stick welding electrodes (continued)
burning too fast on one side, 81
for cast iron, 222
characteristics, 87–88
classifications, 89–90
covered, 93
defined, 87
exposure to moisture/air, 89
fast fi ll and fast freeze, 268
in fl at surface welding, 97
fl ux, 16, 93
handling, 80
iron powder, 88
keeping dry, 80
material matching, 88
7018 and 7028, 268–269
6010 and 6011, 268
sizes, 88
soft arc designation, 88
storage oven, 90
strength, 88
stubs, 75
types of, 87
understanding, 87–90
in vertical-down welding, 100
wasting, 74
welding positions and, 88
stick welding machines. See also welding
machines
AC versus DC, 64, 76–77
in cast iron welding, 223
defined, 64
differences, 76–80
duty cycle, 77
generators, 77, 78
illustrated, 65
inspecting, 90
inverter, 79
maintenance, 311–312
output rating, 77
polarity, 64, 76–77
power source, 77–79
setting, 90–93
setting up, 79–80
transformer, 77, 78, 341
stitch welds, 337
storage, 67
stored energy welding, 337
straight lines
oxyfuel cutting, 181–182
plasma arc cutting, 173–176
straightedges, 59, 60
strength
base metal, 265
defi ned, 12, 22
repair weld, 259
requirements, weld meeting, 305
tensile, 88, 218, 338
yield, 219
striking an arc (stick welding)
defined, 93–94
scratching method, 95
success factors and, 94–95
tapping method, 95
striking the arc (tig welding)
with DC, 127
preparation, 126
remote control device, 126–127
scratch starting, 126
string bead welding, 337
stud welding, 338
submerged arc welding (SAW), 338
subsurface cracks, 269
sugar, 338
• T •
T joints. See also joints
defined, 131
illustrated, 132
lateral, 214
pipe welding, 214
tig welding process, 132
tack welding
campfi re grill, 253
defi ned, 99, 338
portable welding cart, 244
torch cart project, 236–237
tape measures, 59, 267, 307
tapping method, stick welding, 95
temper colors, 338
temperature indicating crayon, 223Index 359
tempering, 338
tensile strength, 88, 218, 338
tension test, 338
thermit mixture, 339
thermit mold, 339
thermit reaction, 339
thermit welding, 339
thick plates, 270
thoriated electrodes, 117
thoriated tungsten, 339
3/8-inch electric drills, 277–278
throat depth, 339
tig torches
defined, 112
holding, 127
illustrated, 113
striking the arc, 126–127
using, 125–127
tig welding
advantages, 17, 106–107
aluminum, 30, 125
amperage control, 115
butt joints, 129–130
characteristics, 105
components, 106
current control, 115
defi ned, 17, 339
disadvantages, 107
drawbacks, 17
electrical current selection, 125–126
equipment, 110–117
fi ller metal, 116–117
fi ller rods for, 116
fi rst weld, 128–129
how it works, 17
lap joints, 130–131
metals for, 108–109
practicing, 119–132
quality welds, 109
setting up for, 119–123
setup, 110
shielding gas, 106, 109, 112–115, 122–123
stainless steel, 28, 125
steel, 26, 124
striking the arc, 126–127
T joints, 131–132
wind and, 114
tig welding machines
defined, 66
features and controls, 111–112
fully equipped, 111–112
illustrated, 67, 114
maintenance, 314–315
polarity, 66
starting modes, 111
for stick welding, 111
timers, 112
tig welding tungsten electrodes, 106, 112
breaking, 121
contamination, 121–122
diameters, 117
green, 117
grinding, 121
as non-consumable, 120
red, 117
shaping tip of, 117
thorium alloy, 117
types and applications, 120–121
toe, weld, 339
toolboxes
illustrated, 283
sizes, 283
as top tool, 282
tools, most wanted
air compressor, 277
bench grinder, 281–282
bottle jack, 282
cutoff saw, 280–281
4 1/2-inch grinder, 276
hacksaw, 276
steel sawhorses, 278–280
3/8-inch electric drill, 277–278
toolbox, 282–283
wrench set, 278
torch cart. See also projects
angle irons, 237–238
base and handle welds, 237–238
base pieces, 234
benefits, 231
box, 238–240
box pieces, 234
creating, 231–242
design, 232
distortion, 236360 Welding For Dummies
torch cart (continued)
gas cylinders, 232
illustrated, 232
materials, 233
paint, 242
partially welded, 239
pieces, cutting, 236
pieces, measuring, 235–236
steel pieces, 233–234
steel pieces illustration, 235
tack welding, 236
welds, 236–240
welds, checking, 241
wheels, 234, 240–241
torches
brazing, 196, 197
defi ned, 323, 341
fusion welding, 198
gas, 187, 189, 191–193
oxyfuel, 168, 179–181
plasma cutting, 163–164, 175, 176, 177–178
soldering, 201, 202
tig, 112–113, 125–127
transformers, stick welding machines, 77,
78, 341
traverse seam welding, 339
tungsten electrodes. See tig welding
tungsten electrodes
2G vertical fi xed position open root pipe
weld, 213
• U •
ultrasonic testing, 339
underbead cracks, 340
undercutting. See also defects
causes, 294
defi ned, 211, 293, 340
illustrated, 294
no, as sign of good weld, 304
in pipe welding, 211
underfill, 304
upset welding, 340
used welding machines, 63–64
• V •
ventilation
importance, 43
need for, 42–43
for repairs, 268
in welding shop location selection, 54
vertical stick welding
types of, 97–98
vertical-down, 98, 100
vertical-up, 98–99
vertical welding
defined, 340
mig welding, 154
pipe welding, 213
vise grips, 59, 308
vises, 69
voltage, for mig welds, 145, 150–151
V-shaped grooves, 222, 292
• W •
wall clocks, 69
wandering block sequence, 340
wandering sequence, 340
warpage, 298
weathered steel, 23
weaving, 340
weld gauge, 341
weld metal, 341
weldability, 341
welding. See also mig welding; stick
welding; tig welding
braze, 195–197
cast iron, 221–228
defined, 10
fusion, 197–199
future of, 18
gas, 187–194
history, 11
importance of, 10
methods, 15–18
oxyfuel/oxyacetylene, 18
pipe, 205–215Index 361
safety, 14, 33–52
technique, 341
uses, 10–11
welding cables, 83
welding curtains, 69
welding educators, 287
welding engineers, 287
welding helmets. See helmets, welding
welding inspectors, 287
welding machines
carriage, 68
current, 62
defined, 62
duty cycle, 62, 77
material type/size and, 63
mig, 65–66
new, 63
plasma arc cutting, 161, 163–164
power source, 62
for repairs, 267
stick, 64–65, 76–80
tig, 66–67, 111–112
used, 63–64
welding pressure, 341
welding procedure qualification record
(WPQR), 215
welding procedure specifi cations (WPS), 215
welding shops
accessories, 67–69
doors, 54
electrical service, 54
equipment, 56–69
fl ame retardant fl oors and walls, 54
housekeeping, 310
indoor versus outdoor, 55–56
lighting, 54
location selection, 53–56
setting up, 53–69
space needs, 54–55
storage, 67
ventilation, 54
welding supervisors, 287
welding symbols, 341
welding tables, 61–62
welding technicians, 287
welding torches. See torches
welding transformer, 77, 78, 341
weldment, 341
welds
axis of, 320
back, 320
backing, 227, 320
bead, 320
butt, 321
butter, 321
campfi re grill, 253, 254
chain intermittent fillet, 322
cold, 322
defined, 340
distributed equally between parts,
301–302
effective length of, 325
face of, 325
field, 325fi
llet, 326
full fillet, 326
full penetration, 304
fusion welding, 199
gas welding, 194
good, signs of, 301–305
groove, 327
horizontal, 328
leakproof, 303
loose, 303
no overlap, 304
no undercutting, 304
plug, 332
portable welding cart, 244
reinforced, 334
root of, 335
seal, 335
shop, 336
size control, 301
slag/shielding material not sticking
to, 302
slot, 336
staggered intermittent fillet, 337
stitch, 337
strength requirements and, 305
surface, no irregularities on, 302
tight, 303
toe of, 339362 Welding For Dummies
welds (mig welding)
beads, 152, 153
depth, 139
excessive penetration, 156
feed speed setting, 145, 150
incomplete fusion, 156
incomplete penetration, 156
tack, 154
vertical, 154
voltage setting, 145
whiskers, 156
welds (pipe welding)
location, 210
1G horizontal rolled open root, 212
penetration, 208
tack, 209, 210
2G vertical fi xed position open root, 213
welds (repair)
aesthetic, 264
cast iron, 263
strength, 259
welds (stick welding)
goal, 95
illustrated examples, 96
width, 75
welds (tig welding)
autogenous, 116
butt joint, 129–130
first, 128–129
lap joint, 130–131
porosity, 109
quality, 109–110
stainless steel, cracking, 108
T joints, 131–132
variables affecting, 111
welds (torch cart project)
base and handle, 237–238
box, 238–240
checking, 241
finalizing, 238–240
grinding, 241
making, 236–240
tack, 236–237
wire brush on, 241
wheels
portable welding table project, 244, 248
torch cart project, 234, 240–241
whiskers, 156
wire brushes, 60, 308
wire feed speed, for mig welds, 145, 150–
151, 341
work space
cleaning, 41
stick welding, setting up, 86–87
WPQR (welding procedure qualification
record), 215
WPS (welding procedure specifications),
215
wrenches
box-end, 278
crescent, 58, 60
maintenance, 308
open-end, 278
sets, 278, 279
wrought iron, color test, 260
• Y •
Y joints, lateral, 214
yield point, 341Apple & Macs
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