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أخوانى فى الله أحضرت لكم كتاب Welding For Dummies Steven Robert Farnsworth Certified welding inspector and instructor
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Learn to: • Work with various welding techniques • Follow safety procedures • Make each joint look professional • Complete simple do-it-yourself projects Making Everything Easier! 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
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