A Few More Welding Questions

July 2, 2011

Question: I was tig welding on a pressure vessel yesterday that was made of stainless. The customer was not going to be using it under pressure. It had some pinholes in it he wanted me to weld up. Every time I welded on it as soon as it cooled it would crack all around the weld! I’d weld the crack and a new one would form! Welded some other stainless for him but this was the only thing that did this. What was I doing wrong? Was running a tig setup off my SA250 and ER308L filler, 2% thoriated tungsten.

 

Welding Pro’s Answer: Probably had moisture in it which caused it to cool too fast.  One solution would be to drill hole in front of crack and re-weld and let cool and then fill hole.

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Question: Does an arc welder have to warm up?

 

Welding Pro’s Answer: No

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Question: Why can’t I see the puddle?

 

Welding Pro’s Answer: you must be looking at the fire instead of the puddle

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Question: Do arc welding electrodes cause problems if they are damp?

 

Welding Pro’s Answer: yes they will cause porosity in your welds

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Question: Can I hold an arc rod while welding, to steady it?

 

Welding Pro’s Answer: no, brace one hand with the other and always try to lean on what you are welding

Welding Dangers – Protect Yourself on the Job

June 30, 2011

Safety is a major concern in every job.  Welders are exposed to many hazardous conditions but with proper safety regulations can do their job with confidence.

  • Inhalation of gas fumes

The workplace should be properly ventilated.  Make sure exhaust fans are working properly.  If working in a tight space, be sure to wear a proper hood equipped with a ventilating system or a respirator to provide you with clean fresh breathing air.

  • Welders flash

Exposing your eyes to the ultra violet light created when welding can cause extreme pain, swelling, and even blindness.  Protect your eyes from the rays produced by the arc.  Always wear a fitted welder’s helmet with the proper rated filter lens plate.  Spectators should not be allowed in the welding area, but if necessary be sure they are wearing protective eyewear and stand a safe distance away from the work area.  Cataracts and retinal damage can occur from infrared radiation exposure.

  • Burns and fire

Be sure the work area is free from oil, grease and any flammable materials.  Sparks can fly up to 30 feet.  Drops of molten metal can cause severe burns. Welders must wear protective flame proof clothing. Cover your arms with long sleeves, be sure to wear protective gloves and long pants with rubber boots will protect your legs. Keep gas tanks in the upright position and securely mounted to prevent tipping and possible explosions.

  • Electrocution

Electric shock is one of the most hazardous conditions a welder can face.  Make sure the welding unit is off and unplugged when not in use. The high voltage used in most welding applications can cause serious electrical shock and possible death by electrocution.  Water and electricity are a deadly hazard.  The work area must be dry and never weld in wet conditions. Stand on a rubber mat when welding for added security.  Gloves should be discarded if they have any holes. Never touch a lead from the power source when you are in contact with any grounded metal.

Ear protection is recommended to prevent hearing loss when working in close quarters.

When welding is complete, disconnect and put all equipment safely away.

10 Welding Schools You Should Know About

June 29, 2011

Becoming a welder is a major career move.  The amount of education you pursue depends on how far you want to advance in this profession.  Educated and well trained welders are more valuable to prospective employers – therefore earning higher wages.

Check the trade schools and colleges in your area to see what courses in welding are offered. Visit the American Welding Society website for a list of schools near you.  Here are a few of the top welding schools that can prepare you to become a certified welder.

1.  Lincoln College of Technology – Denver, Colorado and Grand Prairie, Texas

This is another school in the Lincoln group.  Start with basic arc welding safety and applications.  Work your way up to plasma arc cutting techniques.

2.  Advanced Technical Institute (ATI) – Virginia Beach, Virginia

ATI offers a complete welding program that focuses on shipyard and repair facilities.

3.  All State Career – Jefferson Hills, Pennsylvania

Training in welding technology is only offered at Jefferson Hills location.

4.  Fortis College Technical Training School – Ravenna, Ohio and Atlanta, Georgia

Education in industrial welding includes reading prints, knowing welding codes and understanding the different methods of welding.

5.  South Texas Vocational Technical Institute – Several locations

Combination welding techniques and career placement opportunities are provided.

6.  Hobart School of Welding Technology – Troy, Ohio

Take it from the pros; this company has been around since 1930.  Over 80,000 welders have been trained by the Hobart School in Ohio.

7.  Miller-Motte Technical College – Nashville, Tennessee

MMTC provides training in all methods of welding, blueprint reading, safety and robotics.

8.  Environmental Technical Institute – Itasca, Illinois

Here you will teach you all you need to know to prepare for a certification in structural welding.

9.  Commercial Diving Academy – Jacksonville, Florida

This is the school to attend if you are considering working offshore in the oil industry.  They specialize in underwater welding.

10. Lincoln Technical Institute – East Windsor, Connecticut

Lincoln Tech has 22 locations, currently only the East Windsor, CT location offers classes for welding.

Choose an accredited school that has the ability to do the certification testing on completion of your training.  Many of the schools mentioned offer job placement.

Welding Supplies No Professional should be Without

June 28, 2011

To produce outstanding work you must have quality equipment.  Don’t cut corners on power units, welding guns or even consumable electrodes.  Inexpensive welding rods will most likely produce an unacceptable weld.

Some companies do not provide the personal equipment needed to weld safely and effectively.  There are many suppliers of welding supplies to choose from.

Safety equipment

A modern welding hood with a self-tinting lens is a timesaver for busy welders.  Normal viewing through the glass looks like a dark sunglass lens.  When the arc is struck and the sparks start to fly, the lens instantly changes to welding mode to protect the operators eyes from retinal damage.

Protect your arms and body from flying sparks and drips of hot molten metal with a flame resistant jacket.  A stand up collar will protect your neck and tight button or snap cuffs will prevent hot embers from sneaking up your sleeve.

Welding gloves serve a dual purpose in the welding process.  They protect your hands from sparks and provide insulation to prevent electric shock.  Be sure to choose a pair with long cuffs.  Inspect your gloves often for holes and replace them immediately.

Boots should have rubber soles for safety and steel toes if your workplace requires them.

The gasses emitted from any welding process are harmful if inhaled.  A high-end quality respirator is a wise investment for any welding professional.

A first aid kit should always be close by in case of emergency.  Accidents can happen even in the most cautious circumstances.

Fire extinguishers rated for your application must be inspected regularly.

Everyday Tools

A chipping hammer is needed when shielded metal arc welding.  The flux from the stick protects the weld but the slag must be removed when cool.  Hammers come in many shapes and sizes.  Handle choices are wood or coiled metal.  A wire brush is available on some models.

Heat indicators help prevent cracked and warped welds by measuring the surface temperature of the work piece.  The pen sized sticks are available in many different ratings to suit your application.

Pre-Employment Welding Qualification – Can You Pass the Test?

June 27, 2011

Good paying jobs are hard to find and job interviews have become much more invasive over the years.  Personality tests involve the employer to ask you “what if” questions to see how you would respond to a certain situation.  Many times the questions don’t even have anything to do with the job you are applying for.  You have completely filled out the application, crossed your T’s and dotted your I’s.  You want this welding position bad and you even brought a copy of your welding certificate.  The employer calls you back for a second interview.  Part of this requirement is for you to do a test weld for them.  They want to see your work.

Many companies are now asking for a sample of your work before hiring.  You will be asked to do a live demonstration to show your knowledge and skills. In extreme cases they even x-ray your work to be sure the weld is solid and the bead is strong.  The reputation of the company is in your hands.  Poor quality welding can result in defective products.  In the automotive and aeronautic industries, a weak weld could result in a deadly accident.  Companies want to hire the most qualified employees and avoid the risk and costs involved with substandard work.

How can you study for this type of test?  You should already know if you will be plate or pipe welding, and the method of welding based on the job description.  To overcome your nervousness, find out what type of examples they are expecting.  Depending on the company requirements and specifications, you may have to weld several configurations, angles and fittings.  Verify what type of metals you will be using and practice.

Get a good night’s sleep before test day.  Eat a healthy breakfast and try to relax.  Pack up your welding gear the night before.  Don’t forget your welding helmet, gloves, steel toed boots and long sleeve fire retardant shirt.  Bring any certifications you have earned and pack a pencil just in case they have a written quiz.  Arrive at least 10 minutes prior to the scheduled meeting.  Showing you are prompt and prepared could earn you extra points.  Set up your welding station properly and adhere to all safety rules and regulations.  Take your time and do your best.

Welding Certification

June 26, 2011

Welders do not require a special license to practice in their trade.  However, becoming certified for your welding skill shows potential employers you are serious about your work.  A welding certificate is required for many high paying positions.

Types of Certifications

There are many organizations that set standards for the welding profession, the three main associations are:

  • The American Welding Society

The AWS has set codes and standards for the structural welding industry in the United States.  They set the guidelines for building and bridge construction.

  • The American Society of Mechanical Engineers

The ASME oversees codes and regulations for boiler and pressure container manufacturing.

  • The American Petroleum Institute

The API manages the codes for pipeline welding in the gas and oil field.

Certifications are issued according to the method and type of welding.  To get a jump start on a career in welding, the best certifications to get first are the 3G and 4G SMAW combo for carbon steel welding and the 3G MIG welding certification.  Companies looking for welders for field and shop work look favorably at applicants that posses these certifications.

How to get certified

The term “Certified Welder” does not cover all phases of welding.  The certification is only applicable to the particular code and method listed.  There are fees involved with each certification and the costs start at about $200.  Vocational schools that offer welding classes usually offer testing for welding certification under the American Welding Society’s codes.  For pressure container and pipeline welding, you may have to find an accredited testing facility in your area.  Their fees are usually higher than a vocational school.  A qualified, trained representative will be present at the time of the certification testing.  The participant will receive a set of instructions and the materials to do the job.  The representative will determine if the welder passes the test based on several factors including the appearance and strength of the weld.

Research the field you want to work in.  Find out the proper codes and methods your certification will require.  Practice before you take the test and you are on your way to a new career in welding.

More Welding Questions

June 25, 2011

 

Question: So I’m new at welding and I made a mistake today. I was practicing stick welding with my new TigWeld 200 and it was going pretty good. I had safety glasses on and my new miler performance series helmet. I started a weld and thought to myself “I wonder why that’s so bright?”. About when I got to the word bright I realized I hadn’t flipped my helmet down. Is there anything I should expect to happen because of this? Right now my eye kind of aches a bit and I have a headache starting. The flash was a little over an hour ago.

 

Welding Pro’s Answer: You have burned your eyes and it will take a day or two to get over it.  Usually just temporary and if possible do not weld until better.  If it doesn’t improve, obviously, go to the doctor.

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Question: I’m new to welding and I only have a HF 80 amp Inverter stick welder, I think it’s great for the beginer on a dime.  The reason for this post is because I’m having trouble with a consistent bead!?  Most of my beads look like crap.  I’m cleaning the work surface (1/4 in mild steal tacked in a T-joint). I’m using 6013 5/64-3/32-1/8 rod.  It has a good burn to it, I just can’t get it to bead the way I want to!? Are there any good techniques that I can apply or point out something I’m doing worng, please let me know. Or is it just the case of a noob that needs to practice some more.

 

Welding Pro’s Answer: Sounds like a consistent bead is not kept going.  Move in and out of your weld slowly. When you see it cooling (getting a little dark) move back into your puddle and make sure you are tying in to both sides of the metal.

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Question: Need advice on arc test coming up!  This is the thing – I’m applying for a ship builder position which entails welding 1/2 inch plate which I haven’t done yet. I do have my S.M.A.W. certificate which I got in 1999. I’ve only had one welding job since then doing Iron work for 5 months which was welding 1/4 inch angle (single pass).When I was working I was very good at what I did so brushing up wont be a problem.  The problem in which I’m seeking advice is doing multiple passes in vertical and overhead on 1/2 inch.  Any and all advice is being sought. The test is horizontal, vertical and overhead with no backing.

 

Welding Pro’s Answer: The best thing to do is to set your machine on metal other than your test plates.  On the vertical run first bead with a p5 rod. Grind the bead and make sure to get all the slag out.   Turn your machine up hotter and run a second pass making sure to cover your first pass.  Then, go to a low hydrogen rod.  Once you start your puddle go from one side to the other hesitating on each side like you are making a u until you finish the pass. Continue the process until the metal is built up flush.  Then cap.  To weld horizontally, use the same process with a p5 rod for first two passes. Now, use a 3/32 low hi rod.  Start at the top building your puddle and make a c.  Use the same process until the metal is flush enough for a cap.  There are two ways to cap.  Use stringer beads or the same process used in filling gap.  On your stringer beads, run a bead right at the edge of the filled weld.  Then, go in the opposite direction back and forth until capped out.  Overhead with no backing entails starting your bead with your rod almost straight up (with a little angle towards puddle) moving in and out of your puddle until you make your first pass.  Turn the machine up about 10 degrees and start the second pass.  Start puddle and make a c until finished with second pass.  Go to lo-hi rod and start puddle almost straight up and let build up on sides making a c until you cap out.

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Question: How to pass x-ray with stick down hill on pipe xxs – any advice?

 

Welding Pro’s Answer: Need more info but if this is regular carbon steel, temp will be hotter than normal. Put a longer tack on top and bottom.  Start at top with rod making sure bead is going inside keeping rod slightly turned upward unless you hit tight spot; then turn rod downwards to cut through tight place in metal.  Continue to bottom and start on other side at top and go downhill to bottom.  Grind first pass with grinder making sure to get all slag.  Turn machine up a little hotter and run hot pass downhill on both sides.  Brush weld good.  Continue same process until flush.  Then cap building a puddle making an upside down c till reaching bottom both sides.

Underwater Welding Requires Special Training

June 24, 2011

Offshore rigs, ships and underwater pipelines call for the special skills of a certified diver and underwater welder.  There is a reason this is the highest paid class of welders.  There are many risks involved.

Steel is the most common metal to be welded in a submerged environment. Shielded metal arc welding (SMAW) or stick welding provides the best results when used with a waterproof electrode. The electrode (stick) is coated with a special waterproof flux.  During the welding process, while the electrode is ignited, the flux burns as the metal core melts.  The gas emitted from the flux protects the molten metal to prevent contamination.  Friction welding and open water wet welding are used to repair ship hulls.

Hyperbaric or underwater welding can also be accomplished in a dry environment with the use of a specially designed habitat.  For instance, if a pipeline must be repaired, an enclosure is lowered over the area to be repaired.  A remote control from the surface activates the sides and bottom of the unit to make a water tight seal.  The water from inside the enclosure is pumped out creating a high pressure chamber.  The diver enters the chamber through a special hatch.  Welding is accomplished similar to that of land procedures and gas tungsten arc welding (TIG) can also be performed in this state.  Some companies use clear water tight enclosures that allow the diver-welder to work from the outside of the chamber.

Divers must be aware of the hazards of underwater welding.

  • Sharks and marine wildlife can pose problems working under the sea.

  • Visibility under water can be an issue without the proper equipment.  Special diving helmets also serve as a welding helmet to protect the welder from retinal damage caused by the intense ultra violet light from the arc.

  • To prevent injury or death from electric shock, proper attire including rubber gloves must be worn.

  • Build up of toxic gasses can create breathing problems.  In the case of oxygen and hydrogen mixtures, an explosion is possible.

  • The bends is a term used to describe decompression sickness.  Working under high pressure conditions for a long period of time can cause nitrogen bubbles in the blood.  After the project is complete, the diver-welder must regulate his body back to the normal atmosphere by entering a decompression chamber.

Underwater welding is a critical element in the distribution of oil for energy consumption.  Certified Diver-Welders will remain in high demand in the years to come.

A Few Welding Questions

June 23, 2011

Question: I will be welding a few patches in my truck’s frame. I was wondering what rod I should use. My welder is an 250 amp AC forney. What rod would be the best? The frame is fairly rusty.

Welding Pro’s Answer: A 6011 would probably be your best bet, but it would be better to braise it or use a mig welder because of the rust. if it is rusty it is probably thinner and a mig welder uses less heat.

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Question: Sticks sticking! Are there any tricks to keep the electrode from sticking to work on thin metal? I’m having lots of trouble on 18 ga and low amperage.

Welding Pro’s Answer: Turn the heat up or use smaller rods

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Question: Warp Prevention?  Do you have any tips for warp prevention besides not getting so much heat to it?

Welding Pro’s Answer: Tack off in sections, then weld in sections.

Learning How to Weld

June 23, 2011

Perhaps you work in a small machine shop and the boss handed you a welder and told you to fix something.  That is not likely to happen without some guidance.  The truth is many people weld today without any professional education.  Accepting a position as a welder’s apprentice (Helper) is a great opportunity to learn how to weld from an experienced welder.  For a more formal education, there are many schools and resources to obtain training and certification.  If you are considering a career in welding, learn the right way to do the job from a trustworthy source.

High School

Some high schools offer shop classes as an elective.  Industrial arts include woodworking, automotive and metals.  Welding safety and basics are usually taught in the metals class.

Community College

Earn your associates or bachelors degree in welding from a reputable college.  Many classes can be taken at a local Junior college or Votech center to prepare you for your degree.  Classes required for a degree in welding include math, science, and reading blueprints.  You also have business classes available to you if you are considering starting your own welding company.

Trade Schools or Certified Welding Schools

Learning to weld at a trade or welding school has its advantages.  Safety procedures will be the first topic to be addressed.  Hands on training is a better way to learn than a classroom atmosphere.  Many schools allow each student to work with his own machine with the guidance of the teacher.

Online Courses

As with just about anything today, information is available on the internet.  Online classes are available on many subjects pertaining to a welding career.  Consider taking online classes to learn about the safety measures that must be taken and basics of the electricity involved with the welding process.  Online courses are provided by welding manufacturers, colleges and independent educators.  Only consider accredited schools.  Obviously, online instruction should be considered by those welders with a solid understanding of the basics and are just looking to add to their knowledge base.  Nothing takes the place of hands-on instruction.

Welding takes skill, practice and lots of patience.  Even after one gets a handle on the basics, much more experience and instruction is needed to be competitive in today’s job market against professional welders.  Learning how to weld in shop does not make you a welder.

Welding can be a dangerous profession so take the time to learn every detail of welding before picking up a welding gun or torch.