WELDING FOR BEGINNERS

The Most Complete Easy-To-Follow Guide For Beginners To

Learn How To Weld, Cut, And Shape Metal In No Time With
Pictures And Useful Tips And Tricks

Marc Fuller
Copyright © 2022 by Marc Fuller

All rights reserved. No part of this book may be reproduced or transmitted by

any means, including photocopying and recording by either electronic or
mechanical methods, without the publisher's written permission.
Contents
Introduction
Fundamental Principles Of Welding
So, What Happens When You Weld?
Safety Rules To Follow As A Welder
Basic Weld Joint Designs
Major Types Of Welding Processes
STICK WELDING- SHIELDED METAL ARC WELDING (SMAW)
The Working Principle Of Stick Welding.
Basic Set Up For Stick Welding Machine
How Do I Strike And Make An Arc?
What Kind Of Welds Can I Do With A Stick Welder?
Stick Welding Equipment And Gears
Classifying And Choosing The Right Electrode.
Uses Of The Most Popular Electrodes
Advantages Of Stick (SMAW) Welding
Disadvantages Of Stick (SMAW) Welding
TIG (TUNGSTEIN INERT GAS) WELDING / GAS TUNGSEN ARCH WELDING (GTAW).
The Working Principle Of TIG Welding.
Basic Setup For TIG Welding
The TIG Welding Torch
TIG Welding Amperage And Polarity
Classifying And Choosing The Right Tungsten Electrode.
Why Are The Tips Of Tungsten Electrodes Shaped?
Point Tipped Electrodes
Balled Tip electrodes
TIG Welding Shielding Gas
Advantages Of TIG (GTAW) Welding.
Disadvantages Of TIG (GTAW) Welding.
MIG (METAL INERT GAS) WELDING/ GAS METAL ARC WELDING (GMAW).
The Working Principle Of MIG Welding
The Basic Setup For MIG Welding
Push VS Pull In MIG Welding- Which Method Is Better?
Advantages Of MIG Welding
Disadvantages Of MIG Welding
FCAW (FLUX-CORED ARC WELDING)
The Working Principle Of FCAW
Electrode Classification And Types Used For FCAW
Proper FCAW Welding Machine Settings.
Advantages Of FCAW
Disadvantage Of FCAW.
GAS WELDING (OXY ACETYLENE WELDING).
Working Principle Of Gas Welding
Types Of Oxy Acetylene Welding Flames
Low-Pressure Acetylene Gas Welding
High-Pressure Acetylene Gas Welding
Equipment For Gas Welding
Properly Turning Off The Flame
Choice Of Fuel Gases And Their Uses
Advantages Of Gas Welding
Disadvantages Of Gas Welding
Weldability Of Metals.
Factors That Affect The Weldability Of Metals
Conclusion
Introduction
The term welding as commonly understood by many people simply means
the joining of two metal parts together by applying heat to them. This is a
vague description because welding goes beyond the fusion of metallic parts
together. These welding processes occur in a lot of places ranging from
welding the hinges of your farm gates to complex welds on a construction
site or factories.
In this current age of advancements in construction and fabrication, the
demand for welders is rapidly growing. In construction you could work as a
structural welder, tasked with the cutting of pipes, fabricating parts,
reinforcing concrete, and installing steel columns for bridges, buildings, and
even roads. The advancement of technology in the area of transportation has
also seen an increase in the demand for welders. This means automobile
companies, and the construction of railroads, ships, and airplanes all require a
few welds here and there.
The processes involved in welding are relatively simple and the basic
techniques can be learned easily. As a beginner, there are a few key areas you
need to focus on to get a hang of these welding processes. Hence, whether
you want to choose welding as an active career or learn for some little DIY
project, welding can be interesting and profitable at the same time.
Fundamental Principles Of Welding
Welding can be defined as a fabrication process involving the joining of
metals by the application of heat at a suitable temperature and with or without
pressure or filler materials. This can be divided into two processes, fusion,
and solid-phase welding.
Fusion welding involves the use of sufficient heat to create and
maintain a pool of melted metal in a required quantity. The heat
applied may be electrical or from a gas flame.
On the other hand, solid-phase welding occurs without melting the
metal or addition of filler metals. In this method, you need to apply
pressure to the heated metal.
In welding, the normal electric arc used ranges from 10 – 2000 amps at a
voltage of 10 – 50. The arc column consists mainly of a cathode (for electron
emissions), a gas plasma (to conduct the current), and an anode (region of
electron bombardment). The anode is usually hotter than the cathode from all
the electron activity. The source of power may be from an alternating current
(AC) arc, although the most used is the direct current (DC) arc.
The efficiency of a weld ranges from 60 – 90% depending on the process
because heat is lost through the conduction of the base metal and by radiation
to the surrounding. This means that the total energy put into welding any two
metal parts is much greater than what is required to get the job done in most
cases.
So, What Happens When You Weld?
When extremely heated, metals react to the atmosphere and other metals
close to them, ultimately changing the metal's natural property and the
welded point. For welded metals to fuse, they must flow together in their
molten state before solidifying. However, these melted metals come in
contact with atmospheric oxygen, forming a layer of oxides that prevents
proper bonding with other metal surfaces thus making welded joints very
weak.
To overcome this, fluxes were introduced to fusion welding to serve as a
coating over the molten metal through a controlled reaction that prevents
oxidation. The use of inert gases serves the same purpose for gas-shielded
metal arc welding, where an inert gas flows from an opening around the torch
and displaces the oxygen from the surrounding weld. The argon does not
react to the metal in any way.
It is important to note that the changes in the properties of welded metals
affect their functional capabilities. After welding a joint, there are 3 basic
regions you should take note of:
1. The fusion point (weld metal): this is the point that has been melted
for the welding of the joint.
2. The heat-affected point: this is the surrounding portion whose
mechanical properties have been changed due to the heat from the
welding
3. The unaffected point: this part has not undergone any change in
properties because it was not heated.
Safety Rules To Follow As A Welder
1. Protect yourself from inhaling gases and fumes: exposure to fumes
and gases from welding should be managed by providing enough
ventilation around the work area. In some workspaces, fans, and
ventilation systems are installed to remove fumes and gases. You may
also need to wear a respirator to prevent you from inhaling harmful
fumes.
2. Make proper measures against electrocution: this is one of the most
serious accidents welders should be cautious about. Accidents from
electric shocks could pose immediate and serious life-threatening risks.
Steps to be taken to avoid electrocution may include; using dry gloves
that are in good condition, proper inspection of the electrode holder
before using them, and always, maintaining dry insulation between your
body and the ground or metal to be welded. Finally, to avoid
electrocution do not touch the metal part of your electrode holder with
your skin.
3. Your dress code should be designed for safety: wearing the proper
clothing may be the difference that protects you from electrocution,
burns, and other harm from UV and infrared rays. This means your
clothing should cover your entire body and should not be loose to avoid
flying sparks landing on them and causing a fire. Preferably, wear fire-
resistant clothing in addition to other protective clothing.
The following are also important to PPE you:
Heat protection: as a welder you should wear fire-resistant
overalls, protective gloves to shield your hands, and welding hoods
or goggles.
Ear protection: most welding processes could be noisy for long
periods meaning you may be exposed to noise that could affect your
hearing. Hence you need to use good ear shields to protect your
ears.
Fumes protection: this has been talked about but as a welder, if the
environment has insufficient ventilation, you may use a respirator.
Face and eye protection: this depends on the kind of project to be
handled. This protection may involve the use of safety glasses to
face shields.
Foot protection: proper leg protection should be a leather shoe that
goes beyond your ankles and is fire/ spark resistant. The legs of
your trousers should go over your shoes to protect against flying
sparks getting into your shoe.
Personnel protective equipment for a welder.
4. Avoid clutter in your workspace: clutter around your workspace is one
of the leading causes of fire and explosions in the workplace. Sparks
from a welding arc could jump to about 30 feet in any direction, this
could easily land on any inflammable surface and start a fire. While
working, it is safer to keep only the tools and metals you are working
with within proximity.
5. Always run checks on your equipment before starting any work: a
good welder knows to check his equipment to confirm if it works
properly and is fully grounded before using it. Daily checks are required
because equipment breakdown from time to time and there is no
guarantee that the equipment you worked with yesterday will work
perfectly today. You may have frayed wires, leaking hoses, or cut wires
ready to cause an accident at any time but this can be avoided with these
simple daily checks.
6. Protect yourself from injuries caused by stress: as a welder, you are
exposed to serious injuries from working for prolonged periods. Stress-
related injuries are also a possibility as the body’s performance reduces
over time. You need to take breaks to allow your body to rest before
continuing your project. Also, you may get uncomfortable from being
under all those protective gear for a long time, when you do, take a
pause and get some fresh air. Be careful when you lift heavy metals too
to protect your back from injuries.
7. Always keep updating yourself on the latest safety procedures: the
construction industry always advances with new tools and techniques
discovered constantly. New codes and guidelines are also available from
different companies and national organizations and accessing them are
easier as technology advances. Try to keep yourself updated with these
new guides.
Many manufacturers also outline safety precautions on how to use some
of their tools, make sure you read them and adhere to the instructions.
8. Enforce safety at all times: this is more of a personal effort for you as a
welder. It is not enough to know all these safety procedures without
adhering to them wholly. Also, try to enforce safety amongst people
working around you to avoid an accident from their negligence hurting
you.
Basic Weld Joint Designs
A joint is formed when two or more metal materials are joined together by a
welding process with or without filler material. This join can be formed
between metals of the same or different composition. You need to understand
the relationship between the type of weld joint you produce using a particular
weld, and how they affect the structural quality of your project.
below are 5 basic types of weld joints discussed here at the beginner level.
1. Butt joint

A butt joint is formed when two work metals are placed on the same plane
and their sides welded together. In a simple scenario, it’s just two square
pieces of metal lying flat and joined at the edges. There can be a little space
between them with the weld joining them at that point. This is a very
common type of weld joint used for the fabrication of pipes and structures.
There are various types of butt joint welds which include:
Single Square groove

Single-U groove
 Single-J groove

Double-V groove

Single Bevel groove

Double bevel groove

Before welding, the surfaces may be shaped to improve the strength of the
weld. The edges on both work metals may be shaped or one of them may be
differently shaped. This is done to ensure deeper penetration and to give the
weld a smooth finish.
Several factors determine the type of preparation done for the butt weld for
instance the groove, the wider the groove the more welding would be done to
join the two metals. The structural purpose of the joint and the thickness of
the material determines what type of butt joint should be welded.
There are some defects associated with this type of joint including problems
with porosity, burn-through, and incomplete penetration.
2. Tee joint
A tee joint Is formed when the work metals are joined at 90ᵒ. One of the work
metals provides a flat surface while the edge of the other is joined to it, this
weld always imitates the letter ‘T’.
This type of joint is not restricted to flat surfaces, it can also be used to weld
joints on pipes and tubes. These joints are usually mechanically strong when
welded from both sides. There are easy to weld and require little pre-weld
preparations, they can also be made in different positions (vertical, flat,
overhead, and horizontal).
When making this joint, it is crucial to weld on both of the sides that would
be under structural stress else the joint may fail if pressure is applied on the
side that is not welded. When making you weld, aim to penetrate the joint at
equal angles to ensure deep penetration. If your work metals are of different
thicknesses, focus your weld on the thicker metal.
Lamellar tearing is the major weakness of this weld joint because of
restrictions within the joint. You can use a stopper to prevent this problem.
This joint can be formed using the following weld styles:
Fillet
Square groove weld

J groove weld
 Bevel groove weld

Flare bevel groove weld

3. Lap joint

this joint can be said to be an advanced form of the butt joint. This is when
you weld two metals lying on the same plane together but with one of the
metals resting on top of the other. The weld can be placed on the joints
above and below the overlapping metals.
This joint is preferred when joining two metals of different thicknesses that
cannot be joined with the normal butt joint. This joint can be formed using
the following weld types:
J groove weld
 Bevel groove weld
Plug welds
This type of weld joint although easy to form, cannot be used for joining
thick metals. It is popular for its use in sheet metal work. They may be
subject to lamellar tear and corrosion if not properly done to specification.
4. Corner joint

These joints are similar to the T joint with some differences, notably because
the corner joints have their connecting weld on the corner of the joint while
the T joints are joined in the middle. They are similar because they are both
arranged at a 90ᵒ angle. The corner joint can be an open joint or a closed joint
depending on the strength and application of the weld joint.

These weld joints can be done using various types of welding processes.
The commonly used weld types are:
Fillet weld
J groove weld
 Square groove
V groove
Flare V groove weld
Corner flanging edges
This is also a good joint for sheet metal fabrications. If you want to make a
square frame, boxes, and various shape profiles, then developing great skills
in corner joints is needed.
5. Edge joint

This joint weld type is the most technical of all joints. It is challenging to
weld thin metal sheets when the specifications are complex to follow. This is
formed when two work metals are joined with their edges at an even angle or
plane. This joint is well suited for joints where the stress is reduced.
The common weld types are:
Edge welding joint
Bevel groove weld
Corner flange
U, J and v groove weld.
Major Types Of Welding Processes
The type of welding process you use depends on the material to be welded
and the resources available to you. Some of the processes are also cleaner and
leave a lesser mess for clean-ups, unlike some others. To become a skilled
welder you need to understand and learn these different processes very well.
STICK WELDING- SHIELDED METAL ARC WELDING
(SMAW)

Stick welding also known as shielded metal arc welding (SMAW) is the most
popular of the welding processes. The term “stick” is used to describe the
electrodes usually used for welding. It is a very simple procedure and
versatile used to join metals by using an electric current and an anode (made
up of a solid metal stick covered with metal powder bound together on the
surface).
This welding is used for welding steel or iron and mainly for repairs or
maintenance but can also be employed for construction using heavy steel.
The Working Principle Of Stick Welding.
The type of current used to produce the electric arc between your work
metals and the electrode (stick) can be either AC or DC. This depends on the
electrode type and the kind of job to be done. Most times welders use a DC
power supply with a steady volt and varied amperage ( between 120 – 140
amps) depending on the length of the arc (do you remember P=CV?).
In stick welding, the electrode (coated with a flux) is held with an electrode
holder and connected to a power source that allows current flow through the
electrode, next you connect the ground clamp from the welding machine to
the work metal. On touching the electrode to the work point, electricity
passes from the welding machine through the electrodes and forms an arc on
the point of contact. This raises the temperature to 7,000ᵒ F which melts the
rod and coating of the electrode and creates a flux around the arc. When you
keep moving the electrode along the joint, the rod keeps melting and filling
up the crater between the joints.
The flux from the electrode helps protect the molten metal and the anodes
from oxidation by creating a gas around the weld. This gas slowly settles as
the molten metal begins to cool and forms a slag. The slag is later removed to
give the weld a better and clean finish.
Stick welding although very simple to use requires some level of expertise
and training to achieve quality stick welds. To avoid problems with this weld,
you need to carefully consider the quality of the metals used, the range of the
voltage, and the amperage.
Basic Set Up For Stick Welding Machine
Before setting up your welding machine, you need to make a careful choice
of the required rod ( electrode) before setting the polarity that suits the rod
according to the manufacturer’s instruction, then finally adjusting the
amperage range that will give you the best result.
After fine-tuning your welding machine, you may need to get a piece of
metal with a close enough thickness to the work metal. This is crucial
because different metal thicknesses require different settings. Think of it this
way, a single log of burning wood can melt tin foils but cannot melt a
cooking pot. In the case of welding machine settings, your burning log
represents the amperage. You need to set your welding machine to a high
enough temperature so that the rods do not stick while burning but are not
cherry red which indicates your settings are high.
The polarity settings for a DC power connection should be set using the
image below as a guide.
How Do I Strike And Make An Arc?

Arc welding when is quite simple although as a beginner your biggest

problem would be how to strike and maintain an arc weld. This can be
overcome and mastered if you are patient and dedicate time to it. The best
way to make this journey easy is by acquiring proper knowledge of how it
works and mastering the processes.
You also need constant practice and a good way to do this is by striking small
beads of weld on a piece of scrap metal. This may lead to consuming a lot of
electrodes but it will be worth it in the end so do not despair.
To start an arc, position your electrode about ½ inch from the work area on
which you are welding. Next, jab the area you want to weld then quickly
retract the electrode to the starting position; this is the jab technique. The
striking/ scratching method imitates the action of striking a match but using
your electrode as the match stick and your work metal would be the striking
surface. As a beginner, you will face your electrodes sticking to your weld or
small chipping off from your flux. If your rod sticks to your weld, just
increase your amperage a little and it will be freed. If your flux is cracked,
hold an arc until the electrode burns up to the damaged part.
Once you have struck an arc effortlessly, you can begin holding the arc for
longer periods, and once the weld puddle grows (molten metal), gently move
the electrode along the welding workplace. You should always hold the
electrode about ¼ inch from the puddle to prevent the electrode from going
out. As your electrode burns off, arc length increases and this should be
compensated for by gradually lowering your hand towards your work.
Judging the proper arc length may be tasking for a beginner but you can
measure it by watching and listening to the sounds your arc makes.
If the ac length is too long, you will hear a humming sound and the
arc will be difficult to maintain.
If the arc length is too short, you will hear a pop sound and the
electrodes will keep sticking.
The perfect arc length gives off a sharp crackling sound almost like
frying an egg or bacon.
These movements will come naturally to you as you keep practicing.
you can do simple exercises to practice your distance and hold at home by
placing a washer, a piece of paper, and a pencil. Place the pencil in the
washer and try dragging it along the paper. The main task is to avoid the lead
of your pencil writing on the paper while simultaneously not slipping out of
the washer at any point.
What Kind Of Welds Can I Do With A Stick Welder?
This type of welding works best with thick metals so they are not a great
choice for thin sheet metals. This makes stick welding perfect for structural
fabrications, repairs involving heavy metals, shipbuilding, underwater
welding, mining, steel fabrication, and building constructions. In general any
metal with a thickness of 1/16 or more. You can use stick welders on steel,
chrome, nickel alloys, Stainless steel, and aluminum (not a good choice,
however).
Stick Welding Equipment And Gears
An earth/ ground clamp.
A SMAW welder/power output.
Electrode holder.
Electrodes.
Slag chipper/ hammer.
The welded surface can also be cleaned or freed from slag by using a wire
brush.
Classifying And Choosing The Right Electrode.
There is a wide range of electrodes available in the market for stick welding.
Choosing the right electrode is based on the project you have. The most
commonly used electrodes for welding available are
6010,6011,6012,6013,7014,7015, and 7018. The one with the greatest
welding strength is 7018 but for beginners, 6013 is a great option for use.
These four digits are very symbolic and not just random numbers for each
electrode.
The first two numbers represent the tensile strength of the electrode
in thousands of pounds/square inch. Hence an electrode that starts
with 70 means it has a tensile strength of 70000 psi. This strength
also has to be stronger than the strength of the work metal.
The 3rd number indicates the position where the electrode is to be
used for welding. If it says 0 it means no specific position, 1 means
any position, 2 means flat surfaces or horizontal surfaces, and 3
means flat surfaces only.
The last and 4th number indicates the type of current to be used and
electrode coating.
A summary of the coating and welding current is indicated in the table below:
Digit Coating Current type
0 Cellulose sodium dcep
1 Cellulose potassium dcep,dcen,ac
2 Titania sodium dcen,ac
3 Titania Potassium dcen,ac
4 Iron powder titania dcen,dcep,ac
5 Low hydrogen sodium dcep
6 Low hydrogen dcep,ac
potassium
7 Iron powder iron oxide dcep,ac
8 Iron powder with low dcep,dcnp,ac
hydrogen
Key
Dcep: direct current electrode positive
Dcnp: direct current electrode negative
Ac: alternating current

This universal welding rod classification number series method was adopted
by the American Welding Society (AWS).
Uses Of The Most Popular Electrodes
The following are the most common electrodes used by welders for various
projects;
E6012 and E6013: these are used for thinner/ smaller metals that
don’t easily fit together or form joints.
E6011: these are suited for more complex surfaces with oil, dirt, or
rust. They are widely used with AC or DC polarity and they can
produce a small slag while welding.
E6010: they are rugged and similar to E6011 but differ in the use of
DC only.
E7018 and E7016: the iron powder coating they contain is added to
the flux and this further strengthens the weld. These electrodes
however may be difficult to use by beginners.
Advantages Of Stick (SMAW) Welding
1. Stick produces large arcs that are unaffected by temperature or wind.
2. This type of welding can be done irrespective of oxidation at the
welding point.
3. Stick welding can be used for indoor and outdoor purposes.
4. The polarity of the electrode can be manipulated to reduce the risk of
burning through your work metal.
5. PPE and gear for stick welding are easily affordable and portable.
6. You can adjust your rods for welding different kinds of metals eg
stainless steel, alloys, and many more.
7. Because of the portability of the gear, you can weld in limited spaces.
Disadvantages Of Stick (SMAW) Welding
1. Stick welding leaves slag deposits on the work metal. This requires extra
effort to remove and make your work look neat.
2. Changing of electrodes in between welds interrupts the process and
increases time spent on a job.
3. Stick welding (AC setup) leaves a lot of spatter during the welding
process.
4. Welding metals with a thickness lower than 1/8 inch is very difficult
with stick welding.
5. This method though one of the oldest, is largely manual.
6. Not suitable for reactive metals like titanium because it cannot protect
against oxygen contamination.
SMAW is one of the oldest methods of welding and constantly improving
with advances in technology making it a very effective type of welding. As a
beginner, you need to just work on your selection of the right electrode, speed
of weld, and length of the arc.
TIG (TUNGSTEIN INERT GAS) WELDING / GAS TUNGSEN
ARCH WELDING (GTAW).

TIG welding is another type of manual welding process where the welder
uses both hands in the welding. TIG is also known as Gas Tungsten Arc
Welding (GTAW) which involves the use of TIG electrodes and an electric
arc. TIG differs from other forms of welding because of the way the arcs are
made and filler metals are added. This method of welding is versatile yet
difficult to learn because it requires the expert use of both hands; one for
holding the TIG torch that produces the arc, and the other hand for holding
the filler metal to the weld joint.
This welding process may be slow and expensive but has the highest quality
weld. It can be used to weld various metals with varying thicknesses down to
very light metals.
You may come across the name Heliarc welding although this term is no
longer in use, it was used to describe TIG in early 1940 when the process was
first developed. In its early years, the gas used for the primary shielding from
oxidation was helium
The Working Principle Of TIG Welding.
To understand TIG you need to understand a key component of the process;
tungsten. Tungsten is a hard, slightly radioactive, and breakable metal that is
rarely used in comparison to other metals. In TIG welding, they are made into
non – consumable electrodes used for creating the arc when welding.
Tungsten in TIG welding creates and maintains an arc at temperatures up to
11,000 degrees Fahrenheit without the electrode burning up. The tungsten has
a tensile strength of over 500,000 lbs per square inch, this is extremely high
when compared to the commonly used steel with 36,000 lbs per square inch.
A TIG weld comprises of three main parts, the heat (from the tungsten),
shielding (from a compressed gas), and hand-held filler metal. First, connect
the ground clamp on the work metal before the shielding gas is turned on
which flows through a valve on the TIG torch, this protects the weld area
from the air. This torch is then held over the weld joint without touching the
metal, then the welder presses a pedal with his foot which ignites the tungsten
electrode in the TIG torch and starts an arc.
The extreme heat melts the two metals and creates molten metal which is
filled at the joint by dipping a hand-held welding wire (filler) into the arc.
This creates a beautiful and strong joint.
Basic Setup For TIG Welding
When setting up for a TIG weld, there are some things you need to take note
of. For instance, the power supply for TIG welding is the same as that of stick
welding. The minor differences are the bells and whistles TIG welding
sometimes requires. This means you can connect your TIG torch to the power
supply for a stick weld and still get a perfect result. You can regulate the heat
by adjusting the amperage and the arc length by varying the voltage.
A TIG welder power supply may also contain some features that help the
welder achieve a better result and reduce stress. Some of them are also
designed to enhance the shelf life of some of the welding parts. A few of
these enhancements are explained below:
1. TIG high-frequency start: some power supplies come with a special
feature called the “high-frequency start” that replaces the need to strike
with the tungsten to start an arc. The high-frequency start feature creates
an arc across a gap between the TIG torch and the work metal by briefly
creating a high voltage with enough pressure to jump-start an arc. This
brief spike in voltage drops and the amperage goes back to the set range.
This feature helps protect the tungsten from contamination or
exhaustion.
2. Frequency controls: mostly common when welding on an aluminum or
magnesium metal. This adjusts the properties of the welding arc and
helps give the arc a cleaner finish.
3. Shielding gas flow: this feature may come in two forms either the pre-
flow or the post-flow setting. In the pre-flow setting, the shielding gases
flow to the work area before the arc is started. The post-flow setting
releases the shielding gases after the welding arc is stopped to keep the
weld protected while the molten metal cools and hardens.
The TIG Welding Torch

A TIG torch

A TIG torch consists of some parts as shown in the figure above. The
tungsten (electrode) comes in several sizes and does not burn out like the
electrodes used in stick welding instead they can be sharpened to either a
sharp point or a ballpoint depending on the project you have.
This electrode is held in place by a copper collet but allows the length of the
protruding tungsten to be adjusted. The tungsten also passes through a
ceramic cup whose diameter could be changed if needed.
The body of the collet has some holes used in feeding the shielding gas
around the tungsten.
There are two main types of TIG torches commonly used; air-cooled and
water-cooled TIG torches.
Water-cooled torches: these are torches that use water as a coolant which
makes them more efficient although their maintenance is expensive. They
require a water cooler and a radiator where water passes through.
Air-cooled TIG torches: these are easier to understand and cheap. They are
prone to overheating and a high rate of heat waste.
TIG Welding Amperage And Polarity
Just like stick welding, TIG welding uses AC and DC voltage. DC (direct
current) is a unidirectional flow of electricity from negative to positive just
like the batteries in your flashlight. AC (alternating current) on the other hand
is found in our homes and changes direction so many times.
In TIG welding, there are two connections for the DC voltage polarity setup:
Direct current electrode negative (DCEN): in this connection,
you connect the TIG torch to the negative node of the welder,
allowing electricity to flow from the torch to the work metal. This
leads to heat being passed to the metal and results in a deeper
penetration weld. It also prevents the tungsten from overheating.
Direct current electrode positive (DCEP): here the tungsten torch
is connected to the positive terminal of the welder, this allows
electricity to flow from the work metal to the TIG torch. In this
polarity, heat is passed to the tungsten electrode from the metal.
This connection results in a shallow weld making it suitable for light
sheet metal works.
Classifying And Choosing The Right Tungsten Electrode.
Before choosing a tungsten electrode, you need to consider the polarity of the
current, thickness of the work metal, the power source, and the type of work
metal you are using for your project. Using the correct tungsten electrode
saves you money and time. Using the right electrode also reduces the effort
required to make a clean TIG weld by enhancing performance.
Tungsten electrodes are classified based on their principal oxides and the
percentage of the electrode’s total mass. Hence, they are divided into various
colors to help differentiate them and their uses.
The primary oxides used and examples of electrodes include:
1. Pure Tungsten EWP/WP (green):
Principal oxides: none
This type of electrode can be used with AC or DC and is very stable when
welding, their shielding gas may be argon or Helium. They are cheaper and
mainly used to make clean welds on magnesium and aluminum using ball
ends. They also do not offer tungsten contamination to the weld pool.
2. Lanthanated
These electrodes contain non-radioactive lanthanum oxide (lanthana).
Lanthanated electrodes offer great arcs, great ignition, and a low erosion rate.
There are 3 types of lanthanated electrodes;
Black EWLa-1/WLa 10: primary oxide 0.8 – 1.2%
lanthanium oxide
Gold EWLa-1.5/ WLa 15: primary oxide 1.3 – 1.7%
lanthanium oxide and can be used with DCEN and AC
applications and wide amperage.
Blue EWLa-2/WLa 20: primary oxide 1.8 – 2.2% lanthanium
oxide can be used for DCEN and AC applications. This is the
most popular and versatile tungsten electrode.
3. Thorated
These electrodes are designated EWTh -X and contain Thorium oxide
(Thoria) a radioactive material requiring safety measures when grinding the
electrodes. They have a high emission rate, better arc stability, and better
tungsten contamination resistance.
Yellow EWTh-1/WT10: 0.8 – 1.2% thorium oxide is designed for
DC use with a sharpened point preferable for working on carbon
steel.
Red EWTh-2/WT20: 1.7 – 2.2% thorium oxide has the highest
melting temperature of the tungsten electrodes. This means it has a
lower consumption rate making and is widely used for working on
copper alloy, nickel alloy, and non-corroding steel.
4. Zirconated
These electrodes contain zirconium oxide (zirconia) and are used when the
barest minimum of tungsten contamination is required in the weld pool. They
can be used with DC but more ideally with AC because of its balled end.
White EWZr-8/WZr8: 0.7 – 0.9% zirconium oxide is best used for
the highest weld purity while welding on aluminum and magnesium.
Brown EWZr – 1/WZr 3: 0.15 – 0.5% zirconium oxide is used for
high-quality AC welds using aluminum and magnesium. They are
spatter-resistant and work well on high amperage.
 5. Rare earth mixes EWG
They may contain any variety of rare earth metal oxides which together with
the percentages must be indicated by the manufacturer. Their colors are
mostly purple and can use AC or DC with the ability to withstand high
amperages.

A sample of some tungsten Electrodes

Why Are The Tips Of Tungsten Electrodes Shaped?
Tungsten electrodes are manufactured in a square cut end meaning they have
to be re-shaped. This is important as the shape affects the arc length,
longevity of the electrode, weld penetration, and arc shape. With this in mind,
electrodes are commonly shaped to be pointed, rounded, or tapered with a
ball end.
Point Tipped Electrodes
This type of electrode is used for welding steel using the direct current
electrode negative setting (DCEN). This pointed tip concentrates the
temperature of the arc to the metal by allowing current flow from the
electrode to the metal. Achieving a pointed tip is done by sharpening the
electrode on a grinding wheel or an electrode sharpener, however, care needs
to be taken when doing this because tungsten can be very harmful when the
particles are inhaled.
The electrodes should be sharpened axially (along the length of the electrode)
not radially. This prevents the electrodes from having ridges that can
contaminate the molten metal.
Balled Tip electrodes
This is usually done for the pure tungsten and zirconium-coated electrodes,
making them better for use with AC processes on the GTAW welding
machines.
To create the balled tip, just apply the recommended DCEP amperage
required for the ball diameter. However, care needs to be taken because an
excess in amperage will destroy the tungsten. The ball diameter size should
be below 1.5 the size of the electrode. A larger diameter reduces the arc
stability and may break off, leading to contamination of the molten weld.
TIG Welding Shielding Gas
Just like any other welding process, shielding is required to protect the weld
pool from contamination and TIG welding employs the use of gases. The
most common of these gases used are argon and helium.
Pure argon is the most universally used of the two gases for gas welding on
aluminum and carbon steel. The catch is that they need to be purely inert and
free of CO2 to prevent damage to the tungsten.
The shielding of the weld pool requires a lot of gas, hence to prevent waste,
you need to accurately calculate the flow rate. In general, 6 – 7l/min is
enough during the welding process and could be increased if the weather
condition is windy.
Advantages Of TIG (GTAW) Welding.
1. It can be used to weld metals of various thicknesses.
2. The machines used for TIG welding can be converted for stick welding.
3. Suitable for welding almost all metals and alloys.
4. The use of both hands helps you maintain better control of the weld.
5. It produces high-quality, clean, ductile, and precise welds.
6. This weld can be done in any position both vertical and horizontal.
7. This weld is very good for joining curves.
8. Welders can adjust heat and amperage easily by using the pedals.
9. Produces a cleaner finish because it has lesser smoke, fire, and splatter.
10. The use of fillers helps to seal the weld well hence making the joint
strong.
Disadvantages Of TIG (GTAW) Welding.
1. It is a slow, time-consuming process.
2. This is not portable, making it unsuitable for small outdoor projects.
3. It is difficult to learn and master for beginners.
4. The gas uses and electrodes offer serious health risks and require extra
safety measures.
MIG (METAL INERT GAS) WELDING/ GAS METAL ARC
WELDING (GMAW).

MIG welding much like TIG welding involves welding forming an arc while
continuously feeding a metal strip (filler) into the welding pool where it
burns and helps join the work metal. The major difference however is that in
MIG welding, the filler is fed to the weld pool through the welding and not
by hand.
The shielding gas used in this welding process is also applied through a hose
in the welding gun to help prevent contamination of the weld pool. Unlike in
TIG welding, the electrode (welding wire) is consumed during the process
while making for a clean and effective weld.
This welding is used welding metals with up to ½ inch in thickness and is
fairly easy to learn.
The Working Principle Of MIG Welding
MIG welding is a versatile process for welding both thin sheet and broad
section parts. This technique requires 3 components to be successful; an
electric source to produce heat, an electrode to fill the joint, and a shielding
gas to protect the weld pool from contamination.
Manual MIG welding can be seen as a semi-automatic process because the
power source controls the rate at which the electrode is fed into the weld pool
and the length of the arc while the speed of the weld and position of the arch
is controlled by your hands.
First, the welder squeezes the trigger of the MIG gun, this passes electricity
through the electrode and activates the feeder which continuously feeds a
filler metal to the weld pool. Simultaneously, the weld gun feeds shielding
gas around the weld.
An arc is struck as soon as the electrode comes in contact with the work
metal which begins to melt together with the filler wire continually fed
through the weld gun.
The choice of shielding gas and metal filling depends on the type of weld.
The diameter of the cable (filler) is 0.6 and 1.6mm and the feed speed is
regulated by the welding current.
The Basic Setup For MIG Welding
The MIG setup is simple and comprises of a gas cylinder, the MIG gun, and
the welder.
The gas cylinder usually located at the back of your setup usually holds the
gas for shielding the weld from oxidation. This tank usually contains pure
Argon or a mixture of Argon and carbon dioxide. Using the right gas ensures
you have less spatter and a clean weld. Before any weld, the quantity of gas
should be checked (ranging from 2500 PSI when full to 0 psi when empty),
then set your gauge between 15 – 25 PSI depending on the gun type.
Your choice of a shielding gas depends on the work metal you are working
with. Mainly there are two types of gas mixes are:
Pure CO2 which gives a higher penetration however, it also has a
higher rate of spatter formation.
A mixture of Argon (75%) and CO2 (25%) which works best for all
purposes and with a lower spatter rate. It also reduces the risk of
burning through your work metal.
The MIG welding machine is the central tool for this process. It is the
meeting point of the gas (through a hose), the wire, and electricity combine to
give you a weld through the welding gun. You can also control the polarity of
the electrode and the amperage depending on the thickness of the work metal.
The weld gun has a trigger that enables the feeding of the wire and the flow
of electricity. The speed of the wire fed depends on your settings. The weld
gun also has a copper tip that helps guide the wire and is replaced over time.
The wire also comes in various sizes hence the copper tip also comes in
various sizes. The gun also has a ceramic cup that acts as a stopper to prevent
the electrode from being fed into the weld and also helps in directing the
shielding gas to the right spot while welding. While welding, you need to
watch out for spatter as they can block the nozzle of the welding gun, this
blockage may affect the flow of your shielding gas.
The setup also has a ground clamp that acts as the cathode for the direct
current circuit. This means the clamp is always attached to the work metal or
the metal worktop.

Choosing MIG
Welding Electrodes Or Wire.
In choosing the right MIG welding wire (electrode), you need to consider the
type of work metal, the method of transfer and the position to be welded.
However, some MIG welding machines have a chart to help in your selection
of electrodes.
For the welding wire (electrode), there are various sizes and types used but
the most common for welding carbon steel is ER 70S-6. In some cases, it is
not as straightforward as you may think. You may be required to weld two
different types of metals you need to know what type of wire to use.
The electrodes range in thickness from 0.023 – 0.045 for welding light metals
down to heavy industrial projects. These electrodes are identified by their
standard codes similar o the electrodes used in stick welding.
An electrode designated ER70S-3 means:
ER- indicates an electrode/ filler used for MIG welding
70- indicates the tensile strength is 70000 PSI.
S- solid wire
3- the amount of deoxidizing agent on the electrode.
The electrode comes in two main types ER70S-3 which is a multipurpose
electrode and ER70S- 6 for working on dirty surfaces.
When welding, the length of the wire that is exposed from your welding gun
determines the properties of the weld. The longer the length of wire sticking
out of the gun, the cooler the weld is and the shorter the wire length, the
hotter the weld will be. For thin metals you want your wire to be longer than
the ideal length of 3/8.
Push VS Pull In MIG Welding- Which Method Is Better?
This is an age-long debate among welders, and you could be caught up in the
middle of this argument. The push or pull method refers to the way you
handle the gun while forming your arc. you should note that they are both
great methods with pros and cons but finally depends on the choice of the
welder.
Although many people believe that efficiency differentiates the two methods,
the most noticeable difference is the final appearance.

Pulling/ dragging.
This simply means tilting the welding gun from the starting point and
dragging it along the weld. Imagine you start an arc, then pull the gun
towards you while welding. This cuts more into the work metal and produces
a deeper stronger weld. This is an easier method because it seems more
natural sort of like drawing a straight line.
Pros
This is a very easy MIG welding method.
The unwelded metal part can be used to support and rest your hand.
It is a fast way to weld, especially for time-sensitive projects.
Very effective with flux-cored wire.
Cons
Not aesthetic.
After welding you need to grind to smoothen.
Your hand may impair your vision when welding.
The surface to be welded needs to be grounded to make the pulling
smooth.
Pushing
In this method, as the name implies, you push the welding gun while making
the arc. Imagine moving the gun away from yourself. This makes the hot
weld under your hand while welding. This method makes the weld to be
more symmetrical and flatter.
Pros
This method makes it easier to add weaves to your work.
It provides a better angle for shielding gas coverage.
This is more beautiful to look at.
The resulting welt is flatter and smoother.
Cons
You need to have a steady hand because you can’t rest your hand.
This method cannot be with for flux-cored wires.
Difficult to perform by beginners because it requires mastery.
Advantages Of MIG Welding
1. This produces a clean and ductile weld.
2. Gives room for the welder to control the heat and amperage while
welding.
3. This process can be used to weld all metals and alloys of various
thicknesses.
4. It is more flexible and offers better control since it requires just one
hand.
5. They form welds resistant to corrosion.
6. MIG process can be used in various welding positions.
7. It produces high-quality welds with lesser sparks, smoke, and spatter.
8. The welding machine used can be converted for stick welding.
Disadvantages Of MIG Welding
1. This welding process is slow and consumes time.
2. Regulating the flow of the shielding gas requires expertise, especially for
beginners.
3. It is not flexible enough to be carried about for emergency welding. The
setup is not portable.
4. It Is a complex process to learn and master compared to some welding
processes.
5. The weld pool could be contaminated if the weld gun is blocked by
spatter and unnoticed.
6. High maintenance is required to keep the various parts working
effectively.
FCAW (FLUX-CORED ARC WELDING)

The flux core arc welding technique was invented in the 1950s although not
an entirely new process because it is a variation of the MIG welding
technique. The major difference is the use of a different kind of electrode.
This semi-automatic process uses the same kind of power source with a
continuously fed wire filler, making it fast with a high production rate.
This type of welding is also easy to learn if you can stick weld or MIG weld.
The Working Principle Of FCAW
Flux-cored welding uses heat from the arc to melt the work metal and join a
joint. After the arc is struck, a continuously fed consumable filler and the
work metal both melt in the weld pool to form the joint. Unlike the MIG
process, the fed wire (electrode) is hollow, tubular, and filled with flux rather
than just a solid metal electrode.
This can be divided into two types based on the method of shielding; one of
which is the use of shielding gases and the second is the shielding provided
by the flux core electrode.
Dual Shielding FCAW
In this method of FCAW, an external shielding gas is used to protect the weld
pool from oxidation. The gas is usually stored in a cylinder and connected
through a tube to the weld gun. This serves as additional protection because
the weld pool is already protected by the slag formation from the melting flux
core wire. This is where the process gets the name ‘dual shield’ welding and
serves as an efficient method for welding structural steels. Common gases
used for shielding are pure carbon dioxide or a mixture of carbon dioxide and
argon (25% and 75% respectively).
The mode of transfer of the filler metal into the weld pool depends on the
wire velocity, gases used, and the voltage setting. The spray transfer involves
heating the metal in the anode and then spraying it onto the weld while in the
globular transfer, the metal is heated in its lump form until it melts and drips
onto the weld join. The resulting weld is very strong with the lowest rate of
contamination when compared to other welding types, making it suitable for
welding thick metal materials. It is also a faster method compared to stick
welding but may be limited to indoor use because the gas may be disrupted
by the wind when used outdoors, thus reducing the weld properties.
Flux Core Shielding.
This form of shielding does not require an external shielding gas to protect
the weld pool but the flux-cored electrode. This type of electrode is hollow
and contains slag-forming agents that cover the molten metal and also release
a shielding gas when it comes in contact with heat from the welding arc. this
makes welding outdoors possible without the fear of interruption from the
wind.
Electrode Classification And Types Used For FCAW
The electrodes used for FCAW are visually similar to those used for the MIG
process. However, they differ because the FCAW electrodes are hollow and
filled with flux in the center while MIG electrodes are made of solid metal.
Like other electrodes, these electrodes are also identified by numbers and
letters and they come in various standard sizes, some of which are similar to
those of MIG electrodes but thicker. Some of the major sizes used
industrially are:
0.035
0.045
0.052
1/16
An electrode coded E70T-1 simply means:
E: represents the electrode
7: the minimum tensile strength per square inch of the weld, in this case,
70000 PSI.
0: This indicates the position the electrode is to be used while welding. In this
case, 0 means the electrode can be used vertically and horizontally while 1
would represent all positions.
T: indicates that the electrode is tubular.
1: this indicates the shielding flux type in the electrode.
The flux-cored electrodes need to always be stored in a moisture-proof place
to protect them. Cores that have moisture in them cause the weld to be
defective with wormholes and worm tracks.
Proper FCAW Welding Machine Settings.
The setting for a fluxed core machine is the same as that of a MIG machine.
The main setting chart and manufacturer’s guides are always on a panel in the
machine. These settings include the recommended voltage, speed of the wire,
and metal thickness ranges.
The settings of the voltage are regulated with the recommendations
from the electrode manufacturer. These recommendations are
based on the size of the electrode and the thickness of the work
metal.
The speed of the wire feed regulates the amperage and the transfer
type. The faster the speed of the wire feed, the more contact with
the wire has, meaning the amperage has to be increased.
Advantages Of FCAW
1. This method is preferable for outdoor welding using the flux core
shielding technique.
2. it is suitable for joining metals of all thicknesses.
3. The setup is portable and can be used anywhere.
4. It has a wider range of applications on metal alloys than MIG welding.
5. FCAW is very fast and can be automated for more industrial use.
6. The arc stability provided improves the quality of the weld.
7. It can be used in all positions.
8. It is easier to learn when compared to MIG welding.
9. After welding, little or no effort is required in cleaning the weld area.
Disadvantage Of FCAW.
1. FCAW generates a lot of smoke compared to other welding methods.
2. Porosity could occur from trapped gases within the cooling weld pool.
3. The electrodes require extra care to properly store them, unlike other
electrodes.
4. Flux-cored electrodes are expensive because of the filler materials.
5. To achieve an optimal weld, you need to choose the optimal electrode
else the weld may have defects.
6. The slag formed needs to be removed periodically to achieve a smooth
weld.
7. This method is not recommended for metals with a thin thickness.
Tips On Becoming An Efficient FCAW Welder
1. Check and adjust your polarity
If you are using the FCAW dual shield welding technique, the wires are
usually designated for DCEP use. This means the majority of the heat
generated in the arc will be from the weld metal because it will be connected
to the ground clamp/ anode. In the case of the self-shielding technique, the
wires (electrodes) are designated for DCEN use. The DCEP polarity is prone
to producing spatter because the heat generated is very high for the wire
therefore the penetration with this polarity is not deep.
2. Maintain a clean welding surface before and during welding.
Flux core welding can work fine with a little dust on the work surface, but a
general rule of welding, you want your surface to be very clean before you
apply your weld. Wipe off grease and any liquid from your work surface, and
if there is rust on the metal, grind it off.
While welding, the slag formed should be constantly wiped off this is to
prevent the slag from causing porosity in your weld when it solidifies.
3. Learn how to weld using the drag method.
While welding with the FCAW method, the recommended pattern of welding
is the drag method. This method protects your weld gun from blockage due to
the slag produced by the flux.
 4. Be careful with your travel speed.
Welding can be an art form when done correctly. If you are welding, you
need to move your gun at a fast pace if you want a smaller weld size. You
can also reduce the speed of your wire feed to help you weld at a slower pace
in tandem with the wire feed. This allows you to fill the weld appropriately
and produce a thick solid weld. Moving too slowly may also affect the
quality of the weld too hence there is a need to find the right balance for your
speed. Also, try to remain calm and comfortable.
GAS WELDING (OXY ACETYLENE WELDING).

Oxyacetylene or gas welding refers to a welding process that uses oxygen

and a fueling gas, usually oxyacetylene. This type of welding is used mainly
for welding thin metal sections. You can also use this type of welding for
freeing worn-out bolts, pre-heating metals to make them easy to bend into
different forms, and for soldering too.
It is very easy to learn as a beginner and portable for outdoor use.
Working Principle Of Gas Welding
Gas welding uses a high-temperature flame produced from the combustion of
a fueling gas (usually acetylene) and pure oxygen. This mixture burns to give
a focused flame with a temperature of 3500 degrees centigrade.
When this very hot flame from the welding torch comes in contact with the
work metals, it melts them into a pool of molten metal which sticks together
after solidifying. During the melting process, a filler rod is also melted into
the weld.
The fueling gas together with the oxygen are each stored in separate
pressurized steel tanks and set behind the welding setup. the two gases flow
through separate hoses and are connected to the welding torch where their
rate of flow is controlled. Joining two metals could also be done without the
use of filler metal.
Types Of Oxy Acetylene Welding Flames
There are three main types of flames produced when performing gas welding
and they are dependent on the amount of oxygen supplied to the mix. To
ignite your torch, you turn on your oxyacetylene valve to 1/8 of a turn, then
slowly increase the oxyacetylene until the flame feathers and stops producing
smoke. Then you open your oxygen valve and adjust the flame to the right
size for your welding. The inner core of the flame is what differentiates the
different types of flames.

The neutral flame

Once you put on the torch, you get a bright uncontrolled flame with smoke or
soot. To achieve a neutral flame, the ratio of oxygen and acetylene mixture
should be equal (1:1). It however increases the concentration of oxygen by
absorbing more from the Atmosphere to complete the combustion and forms
a luminous cone. This flame is normally well-defined and clear, making it
ideal for welding.
As a welder, you are expected to adjust to your flame settings using this as a
reference. This usually gives off a bluish-white luminous cone with the
surroundings being light blue. The core temperature may be up to 585ᵒF
while the outer flame is 2300ᵒF.
The oxidizing flame
This flame is gotten by increasing the volume of oxygen slightly above the
volume of acetylene usually in the ratio of 2:1. This flame setting is done by
first achieving a neutral flame and then slightly opening the oxygen valve to
allow more oxygen into the flame until the inner core of the flame shortens.
The flame is distinguished by a hissing sound and its characteristic purple
color.
The temperature for oxidizing flame goes as high as 6300ᵒF at the tip of its
inner core. This is used for welding copper, cast iron, and zinc but not for
steel.
The reducing/ carburizing flame.
This is the final type of flame in gas welding where the acetylene supply is
higher than the oxygen supplied to the flame. This flame has a characteristic
feather edge that extends above the inner core. The length of this feather is a
clue to the quantity of acetylene added to the flame. Meaning if the feather is
twice as long as the core, it means the acetylene is twice as much in the flame

To get this setting, the flame is adjusted to the neutral state then the acetylene
valve is turned on to allow more into the flame. The intensity of this flame is
determined by the length of the feather and ideally, it should not be more than
half the length of the inner core.

Summarily, a reducing flame is made up of 3 parts;

The inner core which is bluish–white.

A white cone

And an outer bluish feather (envelope)

This flame has a coarse sound and can reach temperatures of 3700ᵒF at the tip
of the core. If this method is used for welding, the resulting weld may be
brittle and may crack.
Low-Pressure Acetylene Gas Welding
In this type of welding, low-pressure acetylene is produced in a low-pressure
cylinder by creating an exothermic reaction between calcium carbide and
water.

This acetylene is at low pressure but slightly above atmospheric pressure. A

special type of torch is used to draw the acetylene from the low-pressure
tank. Another type of valve is used on the torch to prevent the acetylene from
flowing back to the tank. This method is not safe because the acetylene
produced contains impurities like ammonia and can easily overheat hence,
they need to be stored in a building to avoid overheating.
This low-pressure gas welding is preferable for welding that requires small
quantities of acetylene.
High-Pressure Acetylene Gas Welding
This method of acetylene welding uses oxygen and acetylene from a high-
pressure tank. They are both usually commercially available in cylinders. The
torch used for this type of welding has two valves for regulating the flow of
oxygen and acetylene and they both connect to a mixing chamber.
This is the most commonly used method of welding because the gases are
readily available commercially in cylinders. It is used for construction work
and maintenance work.
Equipment For Gas Welding
1. The welding torch

This is the central tool for the welding process, this is where the fuel and
oxygen combine to give you the hot flame for welding or cutting metals. It is
made up of two channels where two hoses are connected from the gas
cylinders, separate control valves, a mixer chamber, and a flame tube. It is
designed uniquely to help the welder control the shape and intensity of the
flame by controlling the flow of oxygen or fuel gas into the flame.

2. Gas cylinder and regulators

Gas cylinders used for gas welding are usually differentiated b their colors.
The oxygen cylinder is coded black and has a white shoulder while the
acetylene cylinder is maroon. They may also be labeled to indicate the gas
type they contain. Both cylinders are high pressured with oxygen having
pressure as high as 300 Bar and acetylene, 15 bar.
Regulators are also installed on each cylinder to help in the measurement of
gases. It is important to fit each cylinder with regulators that match the
pressure of the gas used. The regulator and cylinder for the fuel gas are left-
hand threaded while the oxygen regulator and cylinder are right-hand
threaded.

3. The nozzles
Depending on the thickness of the metal to be welded this can be light-duty
(for sheet steel of 2mm thickness) to heavy-duty (steel of 25mm in
thickness). Every torch can be equipped with nozzles of different bore
diameters depending on the work material. This varying diameter aids in the
flow rate of the gases for the welding or cutting of metals.
4. Gas hose
Similar to the gas cylinders, the hoses are color coded for proper
identification and to help prevent accidents. The hose runs from the gas
cylinders to the torch. In addition, they are threaded for additional safety, the
oxygen is right-handed and the fuel gas is left-handed.
5. Filler rods and fluxes
This is the wire that is added to the work metal during the welding of joints.
They are made up of similar materials to the work material.
Fluxes are introduced to the weld as liquid, paste, powder or gases sprinkled
on the surface of the work metal. The filler metals may also be dipped in the
flux before use or inert gases are introduced to the weld.
Properly Turning Off The Flame
After welding, you need to learn how to properly turn off the welding gun to
avoid accidents. The following steps will help guide you through it.
1. Turn off your mixing valve

The mixing valve controls the mixed acetylene and oxygen flow into the
torch. This is turned off first and slowly and makes the flame feather.
 2. Turn off the fuel (acetylene) valve.

Slowly turn off the fuel valve until the gas recesses back to the tip of the
torch. Once this is turned off, the flame dies out from the torch.
3. Shut off the oxygen valve
 4. Purge the torch chambers
This is done by pressing the switch on the torch to force out residual mixed
gases from the torch.
 5. Purge the main lines
After welding, you need to turn off and get rid of the fuel and oxygen trapped
in the delivery hoses. First, you turn off the close the supply of each tank,
then open the valves on the welding torch and press the switch again to
release the gases trapped in the hose.
Once you do this, the gauge readers on both tanks should indicate zero,
meaning no gas is left in the hose. Then close all the valves on the torch.
Choice Of Fuel Gases And Their Uses
The combustion of gas fuels occurs in two different phases. The first phase
occurs in the inner core which is composed of fuel gas and oxygen, forming
carbon monoxide and hydrogen. The second phase is the flame in the outer
zone where extra oxygen is provided from the atmosphere.
The various gases are differentiated by their flame temperature, the heat of
combustion, and their ratio of mixture with oxygen. Their performances vary
in terms of their penetration rate, cutting speed, and quality of their cut.
Acetylene
This has the highest flame temperature of all the fuel gases. This heat is
approximately 3160ᵒC compared to propane with 2828ᵒc. this high
temperature makes it have the highest penetration rate of the other gases. The
ratio of oxygen to acetylene for a normal flame is 1:1.
Propane
This fuel gas has a lower temperature when compared to acetylene, but a
higher heat of combustion than acetylene. However, this heat is mostly in the
outer core of the flame.
The penetration is much slower than acetylene but can change with the
introduction of more oxygen because propane has a higher oxygen
requirement than acetylene to achieve its maximum flame temperature.
Hence the mixing ratio of oxygen to propane is 4:1.
Propylene
This product of liquid petroleum gas has a higher flame temperature than
propane but is not as hot as acetylene. It also gives off high heat on the outer
core, making its oxygen requirement higher than acetylene with an oxygen-
propylene ratio of 3:1.
MAPP
This is a mixture of different hydrocarbons but mainly methylacetylene and
propadiene. This produces a flame hotter than propane but lower than
acetylene. The outer flame however produces similar heat to propane and
natural gas.
They can be used for underwater welding because they are safer than
acetylene in such conditions.
Natural gas
This has the lowest penetration power and lowest heat generation of all the
fuel gases.
Fuel Gas Max temp ᵒC Oxygen-gas
ratio
Acetylene 3160 1:1
Propane 2828 4:1
Propylene 2896 3.7:1
Natural gas 2770 2:1
MAPP 2976 3:1

Table: Characteristics of fuel gases.

Advantages Of Gas Welding
1. This process is easy to learn and perform.
2. Gas welding is a cheap type of welding.
3. It is a portable type of welding.
4. They can be used to also cut metals aside from welding.
5. It is suitable for welding in various positions.
6. It can be used in small confined spaces.
7. This welding technique is very versatile.
Disadvantages Of Gas Welding
1. This is not suitable for welding heavy sections.
2. This welding results in a larger area of the metal being heated up.
3. The rate of heating and cooling is slower, although this could be an
advantage in some cases.
4. The temperature of the gas flame is not equal to the temperature of the
arc.
5. There is insufficient shielding of the weld pool.
6. This welding technique exposes you to higher risks because these gases
can explode if not properly handled.
Weldability Of Metals.
The weldability of a metal refers to the ease at which metals get fused
without having defects in the finished product. Almost all metals and
thermoplastics can be welded but they differ in the ease at which they are
welded. When a metal can be welded with any welding process without stress
and yet produce a good weld, the metal is said to have “good weldability”. A
metal with “poor weldability” makes a welder choose from a limited type of
welding process yet aims to produce strong welds.
For a metal to make a god weld joint, it has to process some qualities such as
its tendency to crack, oxidation, structural modification, hardening and
softening of the heat affected zone (HAZ), and its evaporation. Some other
properties of metals determine the ease at which they can form a good weld
joint. These properties include the melting point of the metal, the thermal and
electrical conductivity, expansion on heating, and surface conditions.
These qualities put together affects the quality of the weld and the effort/ skill
required for producing a quality weld
From the above statement, the weldability of a metal is not entirely dependent
on the metal, but by:
1. steps that were taken during the welding procedure.
2. The purpose of the joint weld
3. The fabrication condition under which the weld was made.
To put this view in perspective, aluminum shows poor weldability with stick
welding processes, but very good weldability when it is welded with TIG or
MIG techniques. Steel weld joints show good weldability when subjected to
normal atmospheric conditions but show poor weldability under low
temperatures.
Carbon and other low-alloy steels are the most widely used base metals for
construction welding. The quantity of carbon in these metals determines the
weldability of pure carbon steels. Steel varies in its grade hence, the
weldability also varies but if the carbon content goes beyond 0.3% extra
caution is required to make a strong weld.
Aluminum and related alloys are weldable but the oxide film produced when
they melt tends to interfere with the flow of the molten metal under gas
welding. They offer good weldability when welded using the fusion welding
technique with an alternating current.
Copper and its alloys are weldable but they have a very high rate of
conducting heat (thermal conductivity) which reduces their weldability.
Metals that tend to bend heat waves are better welded using TIG processes.
The steps taken before and after, during, and after the welding procedure can
greatly affect a metal’s weldability.
Factors That Affect The Weldability Of Metals
1. Welding process
There are over 50 different welding processes. They differ in the amount of
pressure, heat applied the method of applying the heat, and pressure. They
may even differ in the equipment used.
2. Metallurgy
This is the study of heating and manipulating the properties of metals to
produce desired products.
3. Joint design
The dimensions, geometry, and patterns of the desired welded joint when
combined may affect the weldability of the metal.
4. Electric resistance
This refers to the opposition or the resistance to the flow of electricity by a
metal. Generally, metals that offer high resistance to electricity require more
heat to melt them and this makes them have poor weldability.
5. Melting point
This is the temperature that is required to convert metal from its solid phase
to liquid or semi-liquid phase. You want metals to have a low melting or
moderate melting point because it means lesser heat would be required to
melt them and start the welding pool. Any metal that has a high melting point
subsequently has poor weldability.
6. Work metal preparation
These are steps you take before you start welding. This includes cleaning
liquid from the metal, cleaning oil from the surface of the metal, and grinding
off the rust from the metal surface.
Conclusion
Welding has been an age-old practice that has evolved over time into a very
important aspect of our advancement. It goes beyond saying that the art is no
longer simply used for construction or maintenance but can be put to more
aesthetics use.
I hope this book guides you through your journey in becoming a successful
welder, feel free to leave a review or comment as I would love to hear from
you and share in your success story.