How to Arc Weld

When we want to make some object there are many components to put together to make a complete workable thing out of them. If it is a thing, small in size, such as, a spoon we can use technique of molding to create it. What if, we want to make a car? We can mold its parts, such as, engine. However, how to mold a car's bodywork with an engine in it? In such situations, the technique of welding comes useful. With its use different parts of the bodywork in a car are welded together to give it an intended shape and strength. Later on, rest of the car parts are fitted inside this bodywork to create a car.

Arc Welding
Arc welding is one such technique used to weld or join objects made of metals such as stainless steel, aluminum, cast irons and such together. Before we get into the technicalities of arc welding different kinds of metal, lets us see how the welder works. It uses electric current (AC or DC) which passes through an electrode to heat, melt and fuse together the edges of the metals in question. There are some arc welding processes where the metal of the electrode, itself, melts to form the weld.

Arc Welding Stainless Steel
One can use this to repair household items such as a cracked sink or a grain bin and save some money. While doing the job, it is essential that one take proper safety precautions to protect himself. For this purpose, welding helmet, leather gloves and other such items to ensure personal safety must be used. The following are welding basics that may come handy while welding stainless steel:

• If you are new to this it will be beneficial to rent a Shielded Metal Arc Welding (SMAW) rather than buying it. Visit a hardware store or a equipment rental agency in your locality for the purpose and also pick up pliers, welding hammer, AWS E308 stick electrode, and wire brush along with it.
• SMAW can be used to weld metal laced with rust, thin paint and oils. It can be used, in windy weather conditions as it does not use a shielding gas. The base metal and the thinness of the electrode affects the quality of weld.
• To use this welder, plug it into a 220 volt outlet.
• See to it that you properly connect the ground cord and the welder-electrode holder cord into the welder.
• Prepare the surface of the stainless steel to weld with the help of wire brush.
• Attach the grounding clamp cord from the welding machine to the steel to be worked on with the help of a clamp.
• Secure an electrode into the welder-electrode holder and lay it close by the stainless steel to weld. Put on your helmet to protect your face and eyes.
• You can strike an electric arc to melt and weld the metal by tapping the electrode on the steel. Tapping the electrode on the steel completes the electrical circuit and when you pull the electrode half a centimeter or less from the metal, it produces an electric arc.
• Start welding the pieces of the steel together by weaving the electrode from side to side and maintain the required distance mentioned above, to maintain the arc.
• After a minute, to let the weld cool, use hammer to chip off the slag (a coating left by the electrode coating on the weld) from the top of the weld.

Arc Welding Sheet Metal
Using SMAW, one can weld dirty metal in wide range of conditions and applications. For welding sheet metal using 3/32-inch, 6011 stick electrode is useful. Some arc welding tips are as follows:

• Set the welder to AC or DC positive and maintain the current at 60 amp. Depending on the thickness of the metal and welding-style you may need to change the amperage needed for the welding.
• Attach the welder to the holder and take precautions for personal safety.
• Touch the tip of the electrode to the metal and start a welding arc.
• Start working on the welding joint and maintain the electrode one-eighth inch above the sheet metal. Push the molten weld puddle along the joint to be made.
• Chip the slag from the weld, before starting after a break.
• A minute or two after finishing the weld, chip the slag from the weld with the hammer and clean it with a wire brush.
• Only after two or three hours, when you are sure that the joint has cooled sufficiently, think about moving the welded metal.

Arc Welding Cast Iron
Cast iron is a difficult metal to weld even for a experienced welder because of its properties of expansion and contraction. It is a skill in demand, as there are numerous applications, where it can be used in strength-required welding jobs such as support beams and base brackets. Arc welding tips and technique that may come useful to complete this job are:

• For this job, you will need nickel welding rods which are also referred as Softweld 55 Ni.
• Brush clean all the areas to be welded. If the need arises, one can clean the area with a grinder. The area, where the grounding rod is to be attached to the metal needs to be properly cleaned.
• Attach the grounding clamp to the metal and maintain the arc welder at the lowest setting possible, at the start, and increase the current depending on the thickness of the cast iron to weld.
• Welding cast iron is a tricky job, and is best done one inch at a time. Let the metal cool, after each stop, to about 100 degrees Fahrenheit. Before resuming the welding, chip the slag off the top of weld.

Arc Welding Thin Metal
Arc welding thin metals is difficult as one can accidentally burn through the metal, rather than create firm weld, and spoil the job. This happens because of the high temperature that arc welders are designed to produce during the welding, and lack of proper care. The following list of instructions describes proper technique to use:

• Clean the area of the metal to weld with a wire brush, as the dirty metals can cause faulty welding.
• By keeping the electrode centered on the weld puddle one can prevent thin metals from full force of the arc.
• Move the electrode along the joint in straight line rather than from side to side, during the welding. This will help in preventing metal from over heating and burn-through.
• As the metal is thin, weld as fast as possible. Maintain proper weld pool between the two metal pieces to weld.
• One can prevent overheating the metal and achieve high quality of weld by welding an inch and skipping some distance. By doing this all around the area to weld, and repeating these steps, one can achieve the desired integrity of weld.

Vertical Arc Welding
Following is a set of instruction that may help you while arc weld vertically:

• Executing vertical, as well as angled, weld is difficult because a welder has to counteract the gravitational force that acts on the molten metal and tries to pull it downward.
• The solution is to weld vertically downward, starting at the top of the weld by holding the electrode pointing up at 15 degrees to horizon.
• This helps in using the pull of gravity to finish the welding rapidly.
• This method is best for welding thin metals.

Arc Welding Aluminum
Welding aluminum is relatively easier than other metals. The instructions for TIG welding in this link might prove helpful to you. Let us take a look at some features of arc welding aluminum.

• Gas Tungsten Arc Welder (GTAW), also referred to as Tungsten Inert Gas (TIG) welding, is the most commonly used equipment to weld aluminum.
• TIG welding techniques used also differs according to the needs.
• This metal has low melting point than steel. Aluminum sheets of 1/8 inch thickness can be firmly weld together by using a 115-volt arc welder.
• While a 230 Volt machine can be used to weld aluminum pieces that are up to ¼ inch thick.

By learning this, one can create artworks of different type and shapes and start a new business to make money. The knowledge also comes handy while doing small-scale repairs at home, or restore a classic car.