Welding For Dummies

Welding For Dummies
اسم المؤلف
Steven Robert Farnsworth
التاريخ
26 يونيو 2020
المشاهدات
التقييم
(لا توجد تقييمات)
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Welding For Dummies
Steven Robert Farnsworth
Certified welding inspector and instructor
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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