Why do I get so much slag on the back side of my torch cuts?

 

The slag on the backside of a torch or plasma cut is also referred to as dross, and whether you are using an oxy-fuel cutting torch or a plasma torch, it’s caused primarily by incorrect travel speed. Beginners often move slowly with the plasma or oxy-fuel cutting torch. The phenomenon is very similar to what we see with travel speeds relative to welding. The only difference is that you aren’t watching the puddle and carrying it across the joint. You're watching the metal be removed. However, the principle is the same. With an oxy-fuel torch, the flame setting is important but the travel speed is critical for a clean cut. Material thickness plays any important role in adjusting either the plasma cutter or the Oxy fuel torch, but when the big variables are correct, clean cuts come down to travel speed.

Most of the time, you can move the torch with either process a bit faster than you think you can if you have the skill. This will help produce a cleaner cut on the back side of your material.

 

 

Are shaded goggles a necessity when cutting with an oxy-fuel torch?

 

Bottom line, proper personal protective equipment eye related or otherwise should always be used when welding or cutting. These are processes that generate light at intensities that are potentially dangerous to the human eye.

The light from an oxy-fuel welding or cutting torch is referred to as visible light similar to looking at the sun for a few seconds or having a flash light beam pointed directly at your eyes at night. This type of light causes temporary blindness, but the effect usually dissipates after a few seconds. But while it's not permanent, it can damage your eyesight over time in the same way that not wearing proper hearing protection can cause permanent hearing impairment over time. Bottom line, you need to wear shaded lenses as a basic safety precaution when using a cutting torch. In addition to protecting against light exposure, they can also protect your eyes against exposure to particulates resulting from dirty tips, malfunctioning torches and other factors. Don’t take unnecessary risks. Eye injuries can be very serious. Always wear proper protection.

 

 

Why is TIG welding Aluminium more difficult than TIG welding steel?

 

People who learn to TIG weld steel often find welding Aluminium bit more difficult. Most of the difficulty stems from the need for cleanliness and oxide removal. This is why we use AC current on aluminium when TIG welding. The AC current removes the oxide and melts the material at the same time. The other important difference between welding steel and aluminium the melting point. The melting temperature of aluminium is approximately half that of steel. This means the welder must develop faster reaction times when moving and dipping the filler, because the melting time is much quicker. It takes practice, time and patience to develop the proper reaction time to the puddle, but when you finally get it, welding aluminium can be a satisfying experience.

 

 

What is the difference between Argon/Co2 mix and Co2 gas use for MIG welding?

 

The two most typical gases used for welding short circuit MIG are CO2 and 75/25 Argon/CO2 mix. For reasons too complex to explain here, MIG welding steel with 100% Argon is not an option. CO2 creates a more erratic arc and a less attractive appearance. The best choice for all of your MIG welding needs and by far the most common gas is 75% Argon and 25% C02. This creates a stable arc, good penetration characteristics and better weld bead appearance, assuming you know what you're doing. The difference in gas can make a huge difference in the quality of your welds. Why do I keep burning through my sheet metal even when my MIG machine is turned way down?

 

Welding thin sheet metal can be tricky. One of the keys to success is pairing the right size filler metal with the material thickness you are welding on. If you find yourself turning down your machine to the point of spitting and sputtering, you may need to move to a smaller electrode. if you're using a 1.2mm wire on 1mm sheet metal, means you need as much electricity to melt the wire as you do to melt the material. This scenario makes it almost impossible to make the welds without burning through. Of course, we’re assuming all variables are appropriate to the equipment you’re using and to your skill level. Reducing the filler (wire) size will allow it to melt at lower temperatures than the material. This is the same principle that governs TIG welding. You wouldn’t want to use 3mm filler when welding 1.2mm material. The filler must always be equal to or less than the material thickness, which is why filler is available in so many different diameters.

 

What is the most important component of learning to TIG weld?

 

A good question, with a much simpler answer than ou might think. Learning to be a competent TIG welder requires two components. The first is learning a little about the process of welding what polarity to use, what cover gas to use, filler metal type and size, and voltage/amperage relationships. These elements make up the science of how a weld works, and you need to understand them in order to under stand what happens during the welding process. The second component is learning the technique of welding. This requires developing eye hand coordination and muscle memory your eyes ability to see the weld, your brain’s ability to process what it sees, and your hands ability to react to the puddle. Some of the most important factors a beginning welder should focus on are comfort, the position of head and hands to maximize visual access to the puddle, and an understanding of how the puddle reacts to things like arc length, torch angle and change in travel speed. Simply put, it takes time and practice to develop the necessary skills to become a competent welder. l have heard several people refer to “hammer welding” sheet metal, what do est hat mean? I'm not entirely certain where the term originated. It certainly isn't used in any code books, but it’s a recognized technique and if you work with thin sheet metal. it's an important technique to learn. When we weld sheet metal on a car, for example, the material is going to distort. There’s no stopping it. So you have one of two choices to fix the distorted panel on that car. You can wipe big globs of a polyester surface enhancer in to the distorted space, or you can hammer weld. Hammer welding is the process of hammering the weld against a dolly to stretch the weld back into place. Welding creates shrinkage, and in order to reverse the shrinkage we have to stretch the material back into place. Hammering the weld on a dolly will return the metal to its original condition. TIG welds are soft enough to hammer, but MIG welds can crack from hammering. This is why, when welders operate sheet metal that will be finished, they usually use the TIG process.

 

Why does my tungsten look black and burnt after welding?

 

TIG welding with a contaminated tungsten can be a frustrating experience. When learning how to TIG weld, you’ll need to maintain a clear path in your work space to the grinder to keep that electrode sharp and clean. As you develop skill, the trips to the grinder will be less frequent. When you weld after dressing the electrode and it turns black and burnt immediately after, it’s because you don't have sufficient post flow to allow the tungsten to cool in a protected atmosphere. Some welding machines establish the post flow automatically, according to the diameter of the tungsten you're using. The more sophisticated machines have a control to adjust the amount of post flow. It’s also possible that you have a loose connection, a hole in the line or even an incorrectly assembled torch. Whichever the case, the black and burnt colouration suggests that the tungsten is not getting enough gas flow after the arc is extinguished.

 

How big can I make a single pass-weld?

Making larger welds on thicker materials is a process of combining several smaller welds fused together to fill the weld iolnt. No matter the process, the puddle can only fuse and penetrate into the base metal so far, unless you’re using a very powerful machine. The knowledge and skill required to perform multi pass welds will change depending on position and process. Different welding positions require different techniques to ensure proper fusion when creating a multi pass weld. So the ultimate answer to the question is: the code book determines how big your single pass weld can be while still maintaining weld integrity with different welding processes. Again, when you begin welding materials thicker than 5mm thick, the situation changes. Joint preparation changes, welding technique changes and the number of welds required to produce the weld changes.

Why Nozzle Gel for MIG Welding is Important ?

MIG nozzle gel does not make the quality of your beads better. It is used to keep spatter buildup from the welding nozzle and the contact tip. As a result, if used properly, your welding gun’s nozzle will last much longer. Also, you will have better gas coverage over your welding puddle, you don’t have to clean the nozzle manually and last but not least you will have less wire feeding problems because it keeps the tip of your welding gun clean.

When to use the welding nozzle gel?

You should use the nozzle gel every time you are welding with a wire feed welder, especially if you are using pure CO2 as shielding gas because it creates more spatter than Argon 75/25 mix. I would say it is even more important when you are welding with self-shielded wire because as you probably already know, flux-cored welding creates a lot bigger mess and there will be more spatter and buildup at your contact tip because of that.

It can also be used when you have to weld in tight spaces where it is impossible to do post-weld grinding and cleaning. You can simply take a painting brush and apply a thin layer of the gel to the surface. By doing that any spatter created while welding will not stick to the base metal. A neat little trick in my opinion.

How to use nozzle gel?

It is not rocket science to use it really. You simply have to dip your contact tip into the gel. First weld for a few minutes so your nozzle is nice and warm, next, you simply take your nozzle and dip it into the gel, about half-inch deep, and take it out right away. If you do not weld before dipping, you will get a huge thick “bloop” on your nozzle. You do not what that much gel.

Next wipe off any excess gel around your nozzle and clean the wire to proceed welding. After 10-15 minutes, repeat the whole process. As an alternative to wiping it off by hand, you can also do a small tack weld on some scrap metal to evaporate the excess gel. Otherwise you might ruin your project by contaminating the weld, the result will be porosity. If it is an important project, it is better not to risk that.

How and why does the MIG nozzle gel work?

The gel itself is not some sort of a magic pill and it will not work if you just use it once. You will have to use the gel regularly to extend the lifetime of your nozzle and tips. As I understand the technology behind the dip itself, by using it over time, you will build up a nice layer of carbon inside your welding nozzle and on your tip. As a result, the spatter will not stick.

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