Welding Basics

Welding has been there in this world for centuries, though now it's very different from what it used to be in the early stages. One of the very first welding attempts by man was called forge welding. Forge welding means joining of two metals through the process of heating, pounding and striking. The first welders in the world were known as blacksmiths, but now times have changed and so the term "blacksmith" is replaced by welders and from metal welding we have progressed to underwater welding. Having a basic knowledge of welding can actually come in handy, if you are performing any type of welding work, in the house, at your workplace or even at your farm.

As the history of welding suggest, it is the act of joining two or more metals in a strong bond and these basics have been used extensively in all areas of our lives from housing to transportation, repairs and sometimes even in personal relations. Learning some welding tips and techniques is a very popular art in the US, as it can be beneficial to anyone young, adult or even elderly; you just need to know some common basics of welding.

Aluminum Welding Basics
Aluminum is a nightmare for welders. It is known to be the hardest metal to weld, because in its ore or alloy form, it has various physical and chemical properties, which should be understood in detail before welding it. As it is mixed with many other metals, it is difficult to decide the melting temperature of aluminum. It doesn't even change color when its heated, which makes it difficult for the welder to spot it. Before you start welding on its mixed metal form, there are some characteristics that you should know about this metal.

• The melting point of aluminum oxide is higher than its base alloys. Aluminum oxide doesn't start to melt until it reaches 3722°F (2050°C).
• It is noticed that hydrogen dissolves in aluminum very easily, the main problem starts when the aluminum is in its solid stage. Hydrogen cannot gel with aluminum. When aluminum is solid it causes problems with porosity in welding.
• If you are planning to do arc welding, aluminum will need a high level of heat, as it is a good conductor of electricity than other metals. The higher the conduction, the lower the heat, because the electrodes allow the electricity to pass easily.
• Any work with aluminum expect the thermal conductivity to be high, because of the specific heat. Thermal conductivity of aluminum is six times hotter than steel, this is because aluminum is more sensitive to heat than other metals.
• The tools required to work with aluminum are TIG welder (Tungsten Inert Gas Welder), good pair of gloves and a good strong welding helmet. Make sure to wear a cotton shirt that is long-sleeved for welding as TIG welding process emits UV rays and it can burn you.
• For welding aluminum, experts say that a mix of argon and helium gas works best and use a steel brush for cleaning.

TIG Welding Basics
It is necessary to have the knowledge of TIG welding basics, which can be used for the welding of any type of metal like stainless steel, carbon steel, nickel alloys, aluminum alloys, titanium alloys, etc. TIG welding is also a kind of shielding arc process, which is very similar to MIG welding. The only difference is the arc is not made of a consumable wire, but of a non-consumable tungsten electrode. Before starting on the TIG welding basics, here are some instructions which you need to remember:

• TIG welding power source should always be a AC/DC welder, which has a duty cycle of at least 60%. The welder should also have a high frequency generator added in the machine. High frequency is required to keep up a stable arc during the zero voltage conditions in the current cycle.
• Always buy a branded torch for TIG welding. The torch will be useful to deliver both shielding gas and electric current to the weld joint. Buy a torch that fits comfortably in your hand. There are many types of torches available like air-cooled or water-cooled, which can make TIG welding easy.

Ultrasonic Welding Basics
When you use ultrasonic welding, you apply high frequency vibrations of an ultrasound to the metal that has to be welded. The welding puts them under pressure and holds them together, until they create a solid state weld. Ultrasonic welding is also used for plastic welding and different types of metals. Let's have a look at some information on ultrasonic welding.

• When you are using an ultrasonic welding, there is no need of bolts, nails, soldering or adhesive to keep the materials bound. Vibrations are used on thermoplastics, as plastic is melted due to vibrations of the ultrasonic.
• These vibrations are produced through a welding sonotrode (welding horn) and they soften the plastic with line of joint. At a later stage, strength of weld is tested by considering the look of the equipment and the materials that are welded.

Flux Wire Welding Basics
Flux wires or flux cored are used by all wire-feed welders. The flux is found inside the wire and its gives out a shielding gas, when the wire is welded. In flux wire welding there is no need of compressed shielding gas, as the wire is deep penetrating like a 6011 stick electrode. Flux wire is ideal in windy conditions and is popular for hobbies and farm work. So let's see some basic information about welding a flux wire.

• Welding solid wires need a shielding gas, which is also called a metal inert gas (MIG). It's available in a cylinder and is either CO₂ or a mixture of CO₂ and argon gas. MIG gas offers you a clean weld without any slag and a minimal spatter and gives you the advantage to weld thinner wires.
• People prefer wire feed welder, because it is easy to use and you are able to support safe distance from the welding process which is very necessary.
• Always use small diameter wire for thin metals and large diameter wire for thick and powerful metals. Make sure you use the correct type of wire for the base metal.
• CO₂ is good for welding steel, but it's not recommended for thin metals, this is where you use C₂₅ gas (argon 75%/CO₂ 25%). For aluminum go for argon.
• Purchase the right kind of wire for welding. Consider the nature of your welding projects and take into account the nature of your metals.

So these were some different types of welding basics that can be very useful for a pro and an amateur. Always use branded equipment and the right safety gear while performing any type of welding task.