How to make a mixture for welding with your own hands

DIY transformer for welding copper wires

When working with electrical engineering, you often have to deal with connecting wires and other contacts to assemble various electrical equipment.

So, at home, it is not uncommon to make such connections in a distribution box, where welding wires is one of the most effective methods.

The article will provide information for beginners who want to do the wiring and connections themselves.

First of all, you need to understand that the distribution box is a very important structure in the power supply system. This object is the hub for all wiring, as well as a place for connecting additional electrical equipment.

 Due to the fact that this design is a very important part of the entire system, it is important to ensure the maximum level of safety for all equipment and installations that are located in the junction box.

To do this, use a reliable connection of wires and other contacts.

The connection of aluminum and copper wires can be made using conventional twisting (not the most reliable method), twisting with mounting caps, by soldering contacts, using terminal blocks or a crimping tool. But the best way to make a reliable connection of homogeneous wires is welding.

If you want to do the work yourself, then use a special machine for welding wires with graphite electrodes. Using welding, you can make a high-quality connection of electrical wires in switches, various lighting devices, sockets, when connecting protective electrical equipment and other devices.

What you need

To perform welding work in an electrical distribution panel, you must have the apparatus itself. Most people prefer to purchase inverter welding machines.

They are small in size, easy to transport, and not heavy. Most models also have an attached strap for easy carrying.

Inverter devices consume a moderate amount of electricity, which does not affect significant voltage interruptions in the electrical network. Average power – 1 kW.

Then you will need welding electrodes for work. Typically, graphite and carbon electrodes are used for welding. At the heart of the electrode is a copper rod. Flux is also needed, which is needed for welding the structure. Be sure to remember that when working with welding, you need to wear safety glasses and gloves.

Additionally, you should prepare consumables that may be needed during installation work - insulating tape, screws. To clean and twist you need a knife and pliers. The welding machine can be replaced with a device similar in operation. Sometimes a transformer is used to weld wires. If it doesn’t exist, then people who understand electrical engineering can make it themselves.

Process description

The process of connecting electrical leads in a junction box is quite simple.
If safety rules are followed, even a beginner can do this work. Before starting work, you should practice on individual metal parts to get used to the operation of the welding machine. You also need to learn how to regulate the temperature of the electrode so that it does not overheat and does not stick at the welding site.

The device is adjusted in accordance with the thickness of the wires that need to be welded and their number. First, using the usual twisting method, you need to fasten the wire strands. Strip about 5 cm from the end of the cord, removing the insulating winding. Then the contacts of the cores can be twisted together, making 6-7 turns.

Flux is poured onto the recesses. When welding, the electrode must be brought to the joint until a copper ball begins to form at the contact point. When the connection has cooled, you need to clean the contact from flux with sandpaper, and then insulate it with tape or heat-shrink tubing.

“Soldering as a form of connection”

Often at home, not everyone has a welding machine with electrodes, or the ability to connect it for work. In this regard, other methods of connecting contacts in a junction box are often used.

The usual method of twisting in such a place is not considered a sufficient way to connect contacts, since it is not reliable enough. When working with welding, twisting is used as preparatory measures. Also, twisting using a plastic cap is not considered a suitable method. Alternative methods to ensure a reliable connection in an electrical distribution panel include soldering and terminal strips.

Purchasing a soldering iron is more affordable than purchasing a welding machine and graphite electrodes. A soldering iron can be purchased in specialized stores with the appropriate operating instructions. The process is quite simple.

 Before soldering, you need to connect the wires in the junction box so as to maximize the contact area of ​​the conductors. You can expose 2-3 centimeters from the end of the wire by removing the insulation.

Then, using the usual twisting method, we fasten the exposed conductors, applying force evenly. 6-7 turns are enough.

Soldering is always done using rosin and soldering flux (tin). After heating the soldering iron, dip the tip into rosin. When it melts, you can apply a layer of rosin to the stripped wire contacts. It is necessary that the rosin is evenly distributed throughout the veins, since it is the basis for applying flux. After the first treatment, a reddish coating appears.

Then a layer of tin is applied on top, heating it so that it begins to flow into the spaces between the turns of the wires. This connection ensures good contact. This method is effective for both copper and aluminum conductors. Professionals do not often resort to this method, as it wastes a lot of time. But if you are doing the wiring at home for yourself, then the process is not limited by time.

Also, for connections, instead of welding using graphite electrodes, you can use a simple fastening - terminal blocks. This design is designed to clamp bare contacts, providing a connection using a metal jumper. The method is effective when it is necessary to connect copper conductors with aluminum ones.

“Welding cables in a box”

We have prepared a video for you in which you will learn how to properly weld wires in a box.

We recommend reading:

Source: https://steelfactoryrus.com/transformator-dlya-svarki-mednyh-provodov-svoimi-rukami/

Homemade mass for a welding machine

It often happens that additional devices of welding machines become unusable due to high loads or low-quality materials. Such equipment also includes magnetic mass.

This mechanism is a device, the essence of which resembles a clothespin - the magnetic mass is attached to the elements being welded. Unlike a clothespin clamp, it can be easily fixed to absolutely any surface, is more reliable and durable, is highly resistant to voltage surges, and its wide area reliably protects the tool from short circuits.

Disadvantages include poor compatibility with small surfaces of objects being welded, the inability to attach to non-ferrous metals, and the need to regularly clean the magnet from metal debris and shavings.

In general, a magnetic mass is a fairly simple and reliable device that you can even make yourself. The design includes such elements as: magnet and contact. Both of them are connected to each other by a special fastener. The weight of the device depends directly on its overall dimensions. Simplicity of design is the key to reliable and functional operation of the mechanism.

How to make your own magnetic mass?

The process of making your own mass is quite simple. The required tools and materials are minimal. For assembly you will need:

1. The magnet is the main element that ensures the strength of the fastening. A fairly powerful and compact magnet can be obtained from failed speakers.
2. Washer - its size should not differ much from the magnet;
3. A nut with a bolt - they will serve as a clamp for the wire.

The assembly process includes 6 sequential steps:

1. The washer is being prepared. For convenience, you should stock up on two units, the size of which will correspond to the selected magnet.
2. The washer, which will be the bottom part of the device, is drilled.
3. Preparation of the bolt, which involves grinding down its top.
4. All elements are assembled into a single structure, which is welded and polished.
5. The magnet is placed on the bolt and secured with a second washer.
6. A ground cable is attached to the rod, and the entire device is tightened with a nut.

Each master determines the feasibility of independently producing mass for a welding machine for himself. Nowadays, the buyer has a fairly large selection of factory-made devices at reasonable prices.

The list of basic devices required for manual electric arc welding includes the following items: electrode holder; welding cable to holder; return cable; ground terminal (ground clamp).

Quite often these components are not of high quality and require immediate replacement. There are times when the contractor will need a replacement after a short period of use.

General recommendations for selection

The choice of any technical device or device requires a careful and attentive approach. A correctly selected ground terminal can protect the performer from electric shock and will guarantee a high-quality and reliable connection. To select the optimal welding work clamp, you should pay attention to the following important aspects .

1. You need to choose well-known and trusted brands , which will help you avoid purchasing counterfeit products. It is very difficult for a person who does not have sufficient experience to distinguish a fake from an original product. Therefore, you need to buy products only from specialized sellers and suppliers.
2. The ground clamp for the welding machine should be selected taking into account the maximum current that the unit produces.
3. Also, the clamp must confidently withstand the weight of the connected cable .
4. a spring acts as a compression mechanism , then its properties should be sufficient for reliable contact with the workpiece.
5. One of the main roles is played by the opening angle of the terminal, the value of which should be sufficient for reliable fastening to parts of various sizes.

Types of ground clamps

Ground clamps for welding machines, depending on the nature of the fixation, can be of several types. Next, we will look at the main types of clamps, as well as their advantages and disadvantages.

Source: https://MyTooling.ru/instrumenty/samodelnaja-massa-dlja-svarochnogo-apparata

DIY welding machine: simple assembly instructions

Due to the fact that ordinary people often need to work with metal in everyday life, many people use welding units. But not everyone can afford to purchase expensive equipment, which is why the question arises of how to assemble a welding machine with your own hands. The manufacturing process will differ depending on the type and design features of the welding device.

Types of Welding Machines

The modern market is filled with a fairly wide variety of welding machines, but not everything is advisable to assemble with your own hands.

Depending on the operating parameters of the devices, the following types of devices are distinguished:

• on alternating current - delivering alternating voltage from the power transformer directly to the welding electrodes;
• on direct current - producing constant voltage at the output of the welding transformer;
• three-phase – connected to a three-phase network;
• inverter devices - delivering pulsed current to the work area.

The first version of the welding unit is the simplest; for the second, you will need to modify the classic transformer device with a rectifier unit and a smoothing filter. Three-phase welding machines are used in industry, so we will not consider the manufacture of such devices for domestic needs.

An inverter or pulse transformer is a rather complex device, so to assemble a homemade inverter you must be able to read schematics and have basic skills in assembling electronic boards.

Since the basis for creating welding equipment is a step-down transformer, we will consider the manufacturing order from the simplest to the more complex.

AC

Classic welding machines operate on this principle: the voltage from the primary winding of 220 V is reduced to 50 - 60 V on the secondary winding and is supplied to the welding electrode with the workpiece.

Before you start making, select all the necessary elements:

• Magnetic core - stacked cores with a sheet thickness of 0.35 - 0.5 mm are considered more profitable, since they provide the least losses in the iron of the welding machine. It is better to use a ready-made core made of transformer steel, since the tightness of the plates plays a fundamental role in the operation of the magnetic circuit.
• Wire for winding coils - the cross-section of the wires is selected depending on the magnitude of the currents flowing in them.
• Insulating materials - the main requirement for both sheet dielectrics and the native coating of wires is resistance to high temperatures. Otherwise, the insulation of the semi-automatic welding machine or transformer will melt and a short circuit will occur, which will lead to breakdown of the device.

Source: https://www.asutpp.ru/kak-sobrat-svarochnyy-apparat-svoimi-rukami.html

Do-it-yourself welding compound. Ground clamps and magnetic devices. Welding alligator clamp

Magnetic mass for welding is a special device that provides reliable fixation on metal surfaces. This allows you to comfortably perform welding work on complex surfaces where the use of classic alligator clips is impossible.

There are many design options that depend on the work conditions. The structure of this device is not particularly complicated. For this reason, some craftsmen prefer to use homemade magnets for welding.

This device is mounted on the working plane of the workpiece . Thanks to the active magnetic field, a strong fastening is achieved, creating a closed electrical circuit - the main condition for the formation of electrical power.

The tool is especially popular among novice welders - it will take a few minutes to familiarize yourself with the principles of the work. Experienced specialists use magnetic mass for welding machines for critical work - welding large-diameter pipes or connecting load-bearing units made of profile materials.

Design of magnetic contact and its characteristics

Consists of two nodes:

1. Cable holder . The ground cable of the welding equipment is attached to it using a bolted connection.
2. Magnetic node . The size of the magnet depends on the design features. Some models are equipped with a mechanism that regulates the pressure of the magnet on the working plane. Professional devices have switches.

The parts are connected to each other by a rigid fastening. The main characteristics of the devices are:

1. Dimensions and weight. Depends on the manufacturer and specific model. The average weight is 1-1.2 kg.
2. The force of attraction to the surface. Varies in the range from 2 to 50 kg.
3. Welding current strength. The maximum value of the parameter is measured in amperes. For entry-level models, it does not exceed 200 A. An advanced tool is capable of operating at 400-500 A.
4. Execution type. They produce special clamps for corners with gap adjustment.

Safety regulations prohibit connecting a cable without a special lug, which is clamped with bolts.

Advantages and disadvantages

- the most common method of joining metal products. The quality of the future connection depends on the integrity of the electrical circuit .

That is why the invention of the device in question aroused serious interest among specialists.

The popularity of magnetic mass for welding is due to the following advantages:

1. Reliable fixation will allow the welder to concentrate on work without being distracted by adjusting the clamp.
2. The working mechanism is a permanent or switchable magnet. Subject to compliance with operating conditions, it can serve for an unlimited period.
3. You do not need any consumables to use the holder.
4. Even compact models have a contact patch sufficient for reliable closure.
5. The device is resistant to sudden voltage changes or temperature changes.
6. The magnet can be attached to any place to create comfortable conditions for making the connection.

Despite the large number of advantages, there are a number of disadvantages:

1. Before use, it is necessary to prepare the surface. The procedure involves removing dirt and foreign particles.
2. There is no possibility of attaching to small parts, for example, a circle with a small cross-section.
3. It is impossible to work with non-ferrous metals because they are not magnetic.

How to use?

The technology for using the device is not complicated. First of all, the welding cable is connected, after which installation begins .

Most units are equipped with switches that activate a magnetic field. At rest, the magnet will not be attracted to the surface.

One person is required for commissioning. After contact with the working plane, the device must be activated. Upon completion of these steps, the clamp is in operating mode.

After completing the work, perform the above steps in reverse order. Do not try to separate the switched-on device from the part - many models have quite high tear strength. In addition, this may damage the latch.

Upon completion of work, you should immediately clean the contact surface of the magnet from metal shavings, since they negatively affect the force of attraction.

Is it worth buying?

The answer to this question can only be given by the master performing the work. For a novice welder who has just started his professional career, this device can make life significantly easier.

If a specialist works primarily with non-ferrous metals, a magnetic clamp will most likely not be useful.

Experienced workers have a set of various clamps for all occasions, including this device.

The cost of the device is quite high. If you have knowledge in the field of electrical engineering, you can try to make it yourself. The technology and manufacturing process will be discussed below.

How to do it yourself?

Experienced craftsmen try to reduce all costs for the purchase of auxiliary and working equipment to a minimum. Due to the simplicity of the design, no special equipment or complex tools are needed for manufacturing .

To assemble a homemade device, you should prepare the following equipment:

1. Magnet . The working part of the unit. It must have sufficient power to securely attach to metal. Magnets from old car speakers with a power of 10-15 W are ideal for this purpose.
2. Two washers . Their size must correspond to the diameter of the magnet.

Sometimes it can be difficult to select washers for the size of the magnet. It is much easier to make washers yourself from sheet metal.

1. A set of hardware for fixing the welding cable.

Algorithm for performing the work:

1. One of the washers will make contact with the working plane. It is necessary to make a hole in it corresponding to the size of the bolt head.
2. The cap is cut to the thickness of the washer.
3. After preliminary preparation, the structure is connected by welding. The product should resemble a mushroom, in which the threaded part of the bolt plays the role of a leg.
4. A magnet is placed on the mushroom. Place a second washer on the reverse side.
5. A welding tip is attached to the thread, and the entire structure is secured with nuts.

Functionality testing is performed only in the field. The quality criterion will be the correct functioning of the welding machine.

DIY welding compound is a great way to save money, as well as a way to test your DIY skills.

A properly assembled device will last no less than the factory clamp.

Conclusion

Magnetic mass is a useful invention that can make life easier for both beginners and experienced welders. The device has many advantages that justify the rather high cost.

The need to have this device in the arsenal depends only on the specific master. Having the appropriate skills, you can assemble a magnetic clamp yourself, using available materials.

Amateur welder Rustam Alievich Kuliev: “ I live in an apartment building, but I have a dacha outside the city, so the time for active use of the welding machine is from May to October. Last year I came across a magnetic clip in a store and bought it. The impressions are twofold - it won’t help welding a frame for grapes, but it will do the job of repairing a fence from the profile. Overall, I’m happy with the purchase: during the work, the mass never fell off .”

» Ground clamp

The list of basic devices required for manual electric arc welding includes the following items: electrode holder; welding cable to holder; return cable; ground terminal (ground clamp).

Quite often these components are not of high quality and require immediate replacement. There are times when the contractor will need a replacement after a short period of use.

Important! If the welding work clamp is faulty, this negatively affects the work process, its productivity, and most importantly, safety for the welder, the stability of the arc, and the quality of the connection.

The choice of any technical device or device requires a careful and attentive approach. A correctly selected ground terminal can protect the performer from electric shock and will guarantee a high-quality and reliable connection. To select the optimal welding work clamp, you should pay attention to the following important aspects .

1. You need to choose well-known and trusted brands , which will help you avoid purchasing counterfeit products. It is very difficult for a person who does not have sufficient experience to distinguish a fake from an original product. Therefore, you need to buy products only from specialized sellers and suppliers.
2. The ground clamp for the welding machine should be selected taking into account the maximum current that the unit produces.
3. Also, the clamp must confidently withstand the weight of the connected cable .
4. a spring acts as a compression mechanism , then its properties should be sufficient for reliable contact with the workpiece.
5. One of the main roles is played by the opening angle of the terminal, the value of which should be sufficient for reliable fastening to parts of various sizes .

1. Welding alligator clamp

crocodile clip (“clothespin”) for grounding , which is attached directly to the part.

Advantages:

• reliability of connection with the surface of the part;
• convenience and speed of use;
• minimum connection resistance;
• the ability to fix parts of various geometric shapes, including those with complex configurations;
• high degree of disclosure.

disadvantages should also be highlighted :

• low, compared to other types, level of strength of some components - spring;
• This type of clamp is used only in cases where it is possible to attach directly to the product.

The alligator clip should be selected based on general recommendations. Terminals of this type are available in three main modifications: ground clamp 300A, 200A and 500A. Depending on the model of the welding machine and the current it produces, you need to determine the optimal modification. To carry out work at a professional level, it is recommended to purchase a 400-500A clamp.

Important! It should be noted that the use of a clothespin clamp when welding large diameter pipes is impossible.

Source: https://bgcrb.ru/dveri/massa-na-svarku-svoimi-rukami-zazhimy-na-massu-i-magnitnye-prisposobleniya/

Welding ground clamp, types of clamps for a welding machine, homemade terminal, holder,

The list of basic devices required for manual electric arc welding includes the following items: electrode holder; welding cable to holder; return cable; ground terminal (ground clamp).

Quite often these components are not of high quality and require immediate replacement. There are times when the contractor will need a replacement after a short period of use.

Important! If the welding work clamp is faulty, this negatively affects the work process, its productivity, and most importantly, safety for the welder, the stability of the arc, and the quality of the connection.

1. Welding alligator clamp

alligator clip (“clothespin”) for grounding , which is attached directly to the part.

Advantages:

• reliability of connection with the surface of the part;
• convenience and speed of use;
• minimum connection resistance;
• the ability to fix parts of various geometric shapes, including those with complex configurations;
• high degree of disclosure.

disadvantages should also be highlighted :

• low, compared to other types, level of strength of some components - spring;
• This type of clamp is used only in cases where it is possible to attach directly to the product.

The alligator clip should be selected based on general recommendations. Terminals of this type are available in three main modifications: ground clamp 300A, 200A and 500A. Depending on the model of the welding machine and the current it produces, you need to determine the optimal modification. To carry out work at a professional level, it is recommended to purchase a 400-500A clamp.

Important!

Source: https://WeldElec.com/svarka/post/osnastka/zazhim-massy/

How to use magnetic mass? And is it worth buying it?

Reading time: 2 minutes

Magnetic terminal, magnet clamp, magnetic contact of welding cable This device has many names. But the essence is always the same: a magnet allows you to quickly and reliably attach it to the ground and start welding.

But what is it? What are the pros and cons of a magnetic ground terminal? How to use it and is it worth buying at all? You will find the answer to these and some other questions in our article.

What it is?

The magnetic contact of a welding cable is a device that is mounted on the surface to be welded (ground) using an active magnetic field. The device is necessary to form a closed electrical circuit. Without this, manual arc welding is impossible.

The magnetic ground clamp is very popular among both beginners and professional welders. Magnetic mass is also often used for DIY welding at home. It quickly and securely attaches to any surface, even curved ones.

2 in 1. magnetic mass and corner for welding with your own hands - Website about

For welding, in addition to working tools, protective devices for the face and hands of the welder, additional devices are also used - they will facilitate the work and allow it to be done accurately and accurately.

Magnetic angles - pure welding gadgets

Any device that simplifies the work has its advantages.

Magnetic holders for welding are a convenient attribute. You can either buy them in a store (for example, in the World of Magnets) or make them yourself.

Warning: the use of homemade, uncertified devices is hazardous to health and may result in defects in manufactured products.

This attribute is useful even when performing simple one-time work; it will facilitate welding of products because:

• Due to the fact that the metal elements are fixed, it is convenient for the welder to work and he gets freedom of action;
• The assembly of a welded structure begins before welding with the fixation of elements, so one person can weld the product - magnetic devices for welding work reduce labor costs;
• Parts secured with welding magnets stand straight and will not move, for this reason a neat weld is obtained:
• When assembling high-precision products, magnets for welding are not only convenient, but necessary;
• With a large number of welding jobs, they reduce the time spent on welding;
• Non-standard parts are securely fastened without additional devices;
• The parts are installed using welding magnets, both horizontally and vertically.

Magnets from well-known manufacturers have a shape that allows you to set angles of 45°, 60°, 90°, 135°, for reliable fastening of parts. A self-made magnet sometimes fell off, but a factory-made product makes it possible to do work at any angle without moving the part.

Types of magnetic holders for welding

For welding metal structures, different magnets are used; they differ in shape and operating principle:

• Simple magnetic corners allow you to install parts at the required angle;
• A magnetic clamp makes it possible to weld structures of any precision and complexity, placing the welded elements at any angle;
• The magnetic clamp is equipped with a switchable or permanent magnet - this allows you to turn off the magnet after welding and remove the clamp without effort;
• Most angles can be installed at different angles - the design allows for welding of varying complexity;
• Different models of angles have different power - for fixing parts with a large mass, and for welding large structures, high-power magnets are required, but for household work and welding small products, low-power welding magnets are needed.

To get good results when welding complex products, you need to simultaneously use different magnetic devices.

Here are the 7 most common:

Magnetic devices. Externally – 2 metal plates connected together, with a magnet installed between them. Angles can be changed or fixed in one position.

Switchable magnets. Allows you to install the parts to be connected by turning on the magnetic field. At the end of welding, it is turned off and removed in one motion. It is easy to remove metal shavings from such a magnet.

Installation magnets. Used to place parts of the structure to be welded in the required position. They may have the ability to turn off, which reduces the impact of the magnetic field and allows you to effortlessly move the device to another location.

Angular constant action

A magnet for welding parts at an angle is a popular device; it is characterized by its low cost and simplicity of design. This device is used to secure metal elements in the desired position when welding various structures.

• It allows you to quickly and reliably assemble parts of the product, and will help when working with steel pipes, profiles and angles, and sheet metal.
• There are 3 types of magnetic corner for welding:

• Hexagonal;
• Triangular;
• Arrow-shaped.

The hexagonal fixture can be installed at angles in:

1. 30 degrees;
2. 60 degrees;
3. 75 degrees.

Triangular and arrow-shaped devices can be installed at angles in:

1. 45 degrees;
2. 90 degrees;
3. 135 degrees.

These devices facilitate the assembly and welding of products and reduce working time. The downside is that the magnet strength is low, for models in the low price category.

Disabled and enabled

1. * switchable magnetic angle for welding structures
2. * includes for welder (switchable, magnet)
3. The use of switchable and switchable magnets makes it possible to reduce and simplify the installation of metal structures.

   They have advantages over permanent magnets:

• Easy to clean the switched-off magnet from small metal;
• Possibility of adjusting the location of parts to be welded when the magnet is turned off;
• Reliable fixation of structural elements when the magnet is turned on in a certain place.

The advantage of such a device is that it is easy to remove after tack work, with just one movement. Magnetic corners can be template or universal. Standard products are made with fixed angles, and universal devices make it possible to weld 2 parts of the structure at any required angle.

Attention! The design sometimes includes a V-shaped groove. It includes the ability for the welder to fix even very small metal parts of any complexity.

Advantages of working with a magnetic square

Inexpensive standard products are suitable for amateur work, but for professional welding you need complex tetrahedral and three-coordinate devices - made of heat-resistant magnets.

A high-quality magnetic holder designed for welding metal structures is tensile strength, can withstand heavy loads, and is resistant to mechanical stress.

A magnetic square that has the required power must reliably hold the parts of the structure to be welded - this will make independent work easier and safer.

Recommendation! To make it easier to remove the magnetic device, it is advisable to use switchable magnetic holders.

It is necessary to select a magnetic holder suitable for the job, taking into account the expected angles of the structure, the weight of the tool used, and the power of the magnet.

What to look for when choosing 

For a professional welder, it is important to choose the right magnets for welding metal products. This will allow you to do the job efficiently without an assistant.

When choosing, you need to remember:

1. 1. Low power welding magnets should not be used when welding heavy structures. Under heavy weight, a weak holder will not be able to fix massive parts. But a device that is too powerful will complicate the work due to its size and large mass. You need a neodymium or regular magnet suitable for a specific task;
   2. Triangular devices are most often used. They can be installed at angles of 45, 90 and 135 degrees;
   3. It is more convenient to use switchable devices. 

Welding work is carried out at a distance from the magnetic device. If it heats up, the qualities of the magnet will disappear. Strong blows also harm him. There are no more restrictions when using magnetic welding devices.

A simple DIY magnetic square

You can make your own simple magnetic welding square from the speaker on your TV. The product will look like this.

Any grade of steel is suitable for the job. The plates for the product are cut out of sheet metal manually, or a grinder is used for the work. The most important thing is to cut the corners of the fixture accurately.

After this, an insert is made that is installed between the 2 plates; it is needed to increase the rigidity of the product and to protect the magnet from metal filings. Any material will do; for example, you can use plywood, from which a triangle blank with a hole is cut out. The insert is made a few millimeters smaller than the plates; this is necessary so that the insert does not interfere during operation.

After this, the elements of the welding angle are assembled together, and, after lubricating the parts with glue, they are secured with aluminum rivets. DIY welding holder plates must be installed parallel to each other.  

• After the glue has hardened, you need to cover the magnetic corner with a primer and paint it in a suitable color.

As a result, you will get a welding angle, similar in its characteristics to the branded magnetic angle. It is important not to heat the magnet during operation, otherwise the high temperature will cause loss of magnetic qualities.

Source: https://xn--d1aspaq3c.xn--p1ai/tehnika/2-v-1-magnitnaya-massa-i-ugolok-dlya-svarki-svoimi-rukami.html

Magnetic mass for welding - Metals and their processing

page » Articles about welding » Welding station » Equipment » Ground clamp

The list of basic devices required for manual electric arc welding includes the following items: electrode holder; welding cable to holder; return cable; ground terminal (ground clamp).

Quite often these components are not of high quality and require immediate replacement. There are times when the contractor will need a replacement after a short period of use.

Important! If the welding work clamp is faulty, this negatively affects the work process, its productivity, and most importantly, safety for the welder, the stability of the arc, and the quality of the connection.

The choice of any technical device or device requires a careful and attentive approach. A correctly selected ground terminal can protect the performer from electric shock and will guarantee a high-quality and reliable connection. To select the optimal welding work clamp, you should pay attention to the following important aspects .

1. You need to choose well-known and trusted brands , which will help you avoid purchasing counterfeit products. It is very difficult for a person who does not have sufficient experience to distinguish a fake from an original product. Therefore, you need to buy products only from specialized sellers and suppliers.
2. The ground clamp for the welding machine should be selected taking into account the maximum current that the unit produces.
3. Also, the clamp must confidently withstand the weight of the connected cable .
4. a spring acts as a compression mechanism , then its properties should be sufficient for reliable contact with the workpiece.
5. One of the main roles is played by the opening angle of the terminal, the value of which should be sufficient for reliable fastening to parts of various sizes.

2. Magnetic mass for welding

Welders quite often use a magnetic ground clamp . This type has a whole range of advantages :

• the ability to attach the contact to any surface or structure, including pipes;
• simplicity of design ensures durability and trouble-free operation;
• the absence of springs and other mechanisms also contributes to long service life;
• a ground magnet for welding is able to withstand voltage surges and not burn out;
• successfully used in hard-to-reach places;
• The large contact area guarantees secure fastening.

Flaws:

• unreliable fastening of the contact to small-area parts , for example, fittings;
• impossibility of securing the clamp to products made of non-ferrous metals;
• the magnet must be periodically cleaned of contaminants , in particular metal shavings;
• Avoid overheating the magnet, otherwise it may demagnetize ; Overheating occurs if the terminal is attached to a dirty surface.

3. Clamp

Clamp -type welding clamps are used less frequently than the two types listed above. This type of terminals also has several advantages :

• high degree of fastening reliability, since fixation is carried out using a hex head screw;
• good contact with the workpiece ensures a smooth transition of current.

The disadvantages include the rather complex structure of the mechanism and the relatively large dimensions of the terminal.

4. Centralizer

In rare cases, experts select a centralizer-type clamp, designed for centering and tacking pipes previously located in the desired position. Can also be used to connect welding parts.

Advantages of this type:

• ensuring tight contact;
• guarantees welding accuracy;
• Suitable for pipes of various diameters.

Flaws:

• limited scope;
• high cost compared to other types of clamps.

We recommend watching the video, which contains recommendations on how to extend the life of the complete mass of the crocodile and which one is better to choose for purchase.

And another review from an experienced welder, which has some tricks.

Popular models

Consider popular welding ground clamps. The market for the sale of welding consumables offers a wide variety of work clamps, both domestic and foreign. Next we will look at the most popular models.

THIS IS INTERESTING: Is aluminum magnetic?

Earth clamp Ergus 300A Pro , manufacturer - Quattro Elementi (Italy). Characteristics : crocodile type; affordable price; high quality; light weight; supports current up to 300A, which is perfect for the home craftsman.

Ground clamp Skrab 27621 300A (in the picture), made in Italy. It is one of the best options for doing work at home.

Popular grounding terminals are models from the Russian manufacturer Kord . The Moscow company offers clamps with various types of mechanisms.

For welding work in industrial or production environments, it is recommended to select a mass clamp of 500A or more.

Elitech 500A mass clamp, made in China.

Important! It should be noted that almost all manufacturers and sellers of welding equipment also offer customers grounding terminals. Therefore, a wide selection of mechanisms is available to beginners and professional welders.

For those who want to create a clamp with their own hands and save money, we suggest that you read the instructions.

Magnetic mass for welding is, if not the most common, then the most desirable, so the process of its manufacture will be shown below.

The process is simple, you will need a minimum of tools, and the parts can be at hand.

The performer will need : a magnet; two washers the size of the magnet can be made from sheet metal; bolt and nut for clamping the welding cable.

The welding mass holder is assembled in several stages :

• At the washer, which will serve as a contact, a hole is drilled corresponding to the diameter of the bolt head;
• the top of the bolt must be ground down to the thickness of the washer;
• then this structure is welded and cleaned; you should get a mushroom-shaped part with a carved stem;
• the magnet is placed on the bolt, with a second washer on top;
• Lastly, the end of the cable is attached to the threaded rod, and the entire structure is tightened with a nut.

This homemade welding compound will be a good option for saving money and is suitable for home craftsmen. Although there are many critics. What to choose, a homemade product, a cheap product or an expensive professional tool, choose for yourself.

Where to buy electrodes of various brands

Choose manufacturers and sellers of welding electrodes by clicking on the link below to the page of our catalog of companies.

Select a company

Source: https://magnetline.ru/metally-i-splavy/magnitnaya-massa-dlya-svarki.html

How to make magnetic mass for a welding machine at home?

Magnetic mass for welding is a special device that provides reliable fixation on metal surfaces. This allows you to comfortably perform welding work on complex surfaces where the use of classic alligator clips is impossible.

There are many design options that depend on the work conditions. The structure of this device is not particularly complicated. For this reason, some craftsmen prefer to use homemade magnets for welding.

What's happened?

This device is mounted on the working plane of the workpiece . Thanks to the active magnetic field, a strong fastening is achieved, creating a closed electrical circuit - the main condition for the formation of an electric welding arc.

The tool is especially popular among novice welders - it will take a few minutes to familiarize yourself with the principles of the work. Experienced specialists use magnetic mass for welding machines for critical work - welding large-diameter pipes or connecting load-bearing units made of profile materials.

How to choose a grounding terminal. How to modify (improve) or make it yourself

 As a rule, the welding machine is equipped with a cheap grounding terminal. But its quality is such that in most cases it quickly fails or is not suitable for the welder for some other reason. You need to go to the store to buy a new terminal.

How to choose from the offered range if you are just starting to weld? What do you need to know for this? Read in the article.

Due to poor contact, the welding process will be constantly interrupted. Therefore, the mass clamp must be selected based on the following considerations:

• Taking into account the maximum operating current of the welding machine;
• It must support the weight of the cable being connected;
• The spring compression force must ensure reliable contact with the product or the copper pad on which it is installed;
• The opening size of the terminal should guarantee reliable fastening on structures of small and large sizes.

Ground terminals come in three types:

• clamp;
• clothespin "Crocodile";
• magnetic clip.

If a situation arises during your work in which it is difficult to grasp with a clamp or crocodile, you can easily do this using a magnetic clamp. With a magnet, you can easily attach to any surface, be it a pipe or a structure of complex shape.

Recommendations on how to extend the life of an alligator clip

The design feature of this welding compound is a spring, which ensures quick fastening to the metal. It is also the “Achilles heel” of the device.

Understanding the operating principle of a crocodile-type mass allows you to extend its life and not ruin it after two or three welding jobs. What is it about. On any clamp there is a strip (copper-plated or brass) that transfers contact from one clamping jaw to another. If you do not monitor its condition and incorrectly connect the mass to the metal, it may deteriorate.

A common malfunction is that a contact that fits with a wire to one clamping jaw may slip through the spring to another. As a result, the spring begins to heat up, which leads to a loss of its hardness and springing properties (in metallurgy, this process is called tempering), aimed at reliable fastening of the clamp to the surface of the metal product. Because of this, the mass is destroyed at a rapid pace.

To maintain working condition, you need to monitor the condition of the strip: it should not touch the metal when connecting. The photos clearly demonstrate what is meant.

Incorrect contact

Correct contact

Buy a crocodile for professional work. What positive aspects does it usually have:

• the design is correct (the strip is recessed so that it cannot be touched)
• quality materials,
• more powerful spring;
• larger girth (sometimes it is simply not replaceable).

Take with a reserve of 400 -500A.

How to improve the ground terminal?

This problem is usually encountered by novice welders. Purchase a budget manual arc welding inverter for welding at home: for a fence, gate, canopy, etc. Such an inverter, costing 6-10 thousand rubles and more, is equipped with a “Crocodile” clothespin.

In addition to other negative aspects of such a clothespin, which were already mentioned above, it most likely has steel jaws coated with a thin layer of galvanic copper (to give the impression that they are copper). It’s very easy to check whether it’s copper or steel; you just need to hold a magnet. If it is magnetic, it means it is steel.

Usually, food-grade stainless steel in an unhardened state is not yet magnetic, but that’s a completely different story (read the article “How to determine what kind of metal”).

What are the dangers of steel jaws? They will get hot - steel is a much worse conductor than copper or brass. To prevent this from happening, you can remake a cheap clothespin that costs 40-50 rubles. (if, of course, you have some copper or brass in your household, for example, a plate or tube, a busbar).

What should be done? You need to unscrew the original jaws, which are held on by bolts, and use them, like a template, to make other jaws. It is enough that in cross-section they represent the Russian letter “P”. Without much effort you will get a good contact on a low-quality clothespin!

Do-it-yourself magnetic clamp for welding

Welders can appreciate the advantage of using a magnetic clamp when working with complex structures where there is simply nowhere to hook a regular crocodile clamp. And here you throw the mass onto the surface of the metal being processed - and you perform welding work.

You can buy it at any welding supply store, but will it meet your needs and be as reliable as a terminal you make yourself? Everyone somehow invents trident holders, some make “crocodiles” in the garage, but few people undertake to invent magnetic masses. In general, do it and you’ll have something to brag about to your welding friends!

• The terminal itself is cut out of 2mm and 0.5mm sheet metal, and the magnet is taken from a non-working speaker; a 20x20x3mm hot-rolled angle segment is also used here as a cable pressure plate. All other components: screws, washers, nuts are standard.
• The connection can be made to the ground cable of the welding machine, replacing the standard “crocodile”, or you can separately equip this type of ground with a bayonet connector and a cable with a cross-section of 1x16mm.

Source: http://svarka-master.ru/vy-bor-zazhima-massy/

DIY spotter compound - Metals, equipment, instructions

A spotter is a device designed to perform spot welding. This equipment is widely used when straightening and restoring car bodies. Due to the simplicity of the design of such devices, making a spotter with your own hands is not difficult.

It is only necessary to use a high-quality inverter, on the basis of which welding equipment is performed.

Features of application

If initially spotters were used only when performing various body works on cars, today, thanks to the versatility of this equipment, it is possible to use it in everyday life for high-quality spot welding . With the help of self-made welding machines, all kinds of metal structures, fences made of reinforcement are made, and the surfaces of body panels are straightened without the need to disassemble the skin.

The main purpose of the spotter is the repair and restoration of car body panels . In cases where it is impossible to align parts from the inside, and their dismantling poses certain difficulties, spotters are used to perform high-quality welding, which will subsequently be perfectly protected from corrosion.

Principle of operation

Today, there are several options for electrical circuits of spotters, which are made from an inverter, a transformer and an old battery.

Homemade devices operate on the principle of a hammer, allowing you to pull out body elements without local painting, and the quality of spot welding when using a working gun allows you to ensure the most reliable and durable fixation of body elements.

A homemade spotter has several operating modes:

• Welding mode, using a carbon electrode, when all work is performed at minimum power.
• A short-term mode in which the guide is secured using special rings and the metal is pulled out when it is heated at a point.

The most popular models of spot welding machines today are those that are based on an inverter. Such devices have a special additional gun, which is used to provide spot heating of the metal elements being connected.

Inverter based device

Homemade spot welding machines, made on the basis of a welding inverter, are distinguished by their simplicity of design, have the power necessary to work with most metals and can be easily made by hand.

The simplest spotters can consist of the following elements:

• Inverter housing.
• Cable.
• A sharp rod or electrode.
• Stadder pistol.

The easiest way to make such a machine for contact welding is using inverters, to which a welding gun is attached via a cable. You can use either ready-made purchased studder guns or make them yourself based on a metal sealant gun.

Advantages of self-made spotters:

• Possibility of pulling out metal parts without damaging the original paint layer.
• Ease of use.
• Versatility of use.
• Possibility of performing metal upsetting using graphite electrodes.
• The presence of two or more modes of welding work.
• Simplicity of design.
• Affordable cost of the components used.

You can find various designs for making inverter spotters. You can choose from the simplest models that are intended for domestic use, as well as professional installations that combine power, versatility of use and advanced capabilities.

To assemble the device yourself, you will need the following components:

• Contact group for 220 Volts.
• Diode bridge.
• 30A control relay.
• A transformer that reduces the voltage by 12 volts.
• Thyristor 200 Volt.
• Control buttons.

Connection to the network is carried out using a diode bridge and a transformer. The thyristor circuit and contact diode group in the inverter increase the voltage, after which the current is supplied through the cable to the working welding gun.

The transistor diode unit used must withstand the highest possible output current, which reaches 1500 Amperes. The power of the output welding current can be controlled using a bus, which is installed instead of the secondary winding.

Despite the apparent complexity, even basic skills in reading electrical diagrams and working with radio components will be enough to independently manufacture spotters, which can be used not only in everyday life, but also for performing various types of body work.

It is only necessary to select a high-quality design of the machine for resistance welding, and subsequently fully adhere to the documentation available on hand.

Housing and cables

The box of a self-made spotter can be made from available metal materials. The easiest way to do this is to use a case from an old computer . The presence of a working fan will be an additional advantage, which will reduce the temperature, allowing you to improve the operating time of the device without turning it off for mandatory cooling.

Inside the case it is necessary to install several fans that operate from 12 Volts and allow for high-quality cooling of the power part of the inverter. The easiest way is to use computer fans that are directly connected to the control unit and run continuously or based on a signal from temperature sensors.

The presence of compact fans inside the case allows you to extend the time of continuous operation of the device at maximum power levels.

It is best to use ready-made purchased welding cables with a cross-section of at least 1 millimeter per 10 Amperes of maximum current rating. For mass, cables with a length of no more than 150 centimeters are used, and the working wire is no longer than 250 centimeters. Otherwise, there may be a loss of current, which negatively affects the operation of the machine and the quality of welding.

Threaded connections are attached to both ends of the cable to fix the welding gun and connect it to the inverter. Due attention should be paid to the quality of the connection, since the loss of welding current depends on this. On the reverse side of the power cable for ground, install a quick-release clamp or use terminals with threaded fastening.

Executing a working gun

The main working element of the spotter is a welding gun , which allows for spot heating of the metal.

If you plan to constantly use the equipment, then it is preferable to purchase a ready-made factory pistol, which is characterized by its simplicity of design, reliability and durability.

If the spotter is made for occasional use, then it is quite possible to assemble a working pistol from improvised devices.

The easiest way to do it is with an assembly glue gun, to which a reliable and comfortable handle made of textolite or other non-conducting materials is attached.

Appropriate holes are made in the glue gun for the guides, to which the electrode used is subsequently fixed.

The cable from the inverter is connected to the gun and when the trigger is pressed, a short powerful pulse is sent.

The holder-holder, which fixes the welding electrode, is made of a rectangular or square copper tube. Copper rods with a diameter of 8-10 millimeters are used as electrodes.

You can find various schemes and options for manufacturing a resistance welding gun, which involve changing the electrode without disassembling the completed device.

Reverse hammer assembly

One of the advantages of using a spotter is the quick replacement of working tools , which expands the functionality of such equipment.

To perform straightening and body welding work, a reverse hammer or, as it is also called, an inopuller, is used. Making a simple reverse hammer with your own hands is not difficult.

It is performed on the basis of a metal mounting gun.

The part that holds the container with sealant and mounting foam is cut off from the old mounting gun. Three rods with a diameter of no more than 10 millimeters are welded onto the vacant area. A ring is fixed to the free ends of the rods by welding, which is made from a rod with a cross-section of 6-10 millimeters. The diameter of the ring should not exceed 100 millimeters.

The stops and the curved part of the gun rod are cut off. Instead, a mount is welded to which the cable from the welding inverter is subsequently connected. The cable can be secured using two nuts and an M10 threaded bolt.

With the help of a reverse hammer, high-quality spot welding and straightening work can be carried out without damaging the original paintwork.

If desired, you can purchase ready-made reverse hammers, which differ in the diameter of the working body and are intended for use on spotters with different powers.

Spotter from a welding machine

The easiest way is to make your own spotter from a welding machine. In this case, you only need to retrofit the unit with a thyristor and a diode with the required parameters, which will allow pulse welding. Additionally, the welding machine can be equipped with an energizing relay, which allows you to regulate the power of the pulse.

  How to make a wooden pointer with your own hands

The spotter from the welding machine is made in full accordance with the existing diagram, and all that remains to be done is to purchase or make your own working gun and return hammer . Some design schemes of the spotter imply the ability to switch operating modes, when the inverter used can operate as a classic welding machine or a spot welding device.

Making a spotter with your own hands is not particularly difficult. You can make such a device for resistance spot welding from an inverter or an old welding machine. You just need to have a high-quality diagram on hand, according to which the device will be assembled.

The working guns and reverse hammers used can be made from devices for spraying polyurethane foam and sealant.

Making such equipment yourself will allow you to significantly save on the purchase of industrially manufactured equipment, while the functionality of homemade equipment will not differ from expensive purchased units.

Source: https://spb-metalloobrabotka.com/massa-dlya-spottera-svoimi-rukami/

Magnetic mass for welding: what is it, where is it used and how to use it correctly

In the work of a welder, devices such as a magnetized contact or a magnetic-based terminal are often used. They greatly simplify the preparatory work.

The magnetic mass is attached to the iron structure and held there. Therefore, you can immediately begin welding work.

In this publication we will try to answer all the questions that arise in the process of using magnetic grounding terminals. Is it worth using it and where is the best place to buy it? You can read about all this in this article.

Introduction

First, let’s define what a magnetic welding cable contact is. This is a kind of auxiliary device.

It is attached to the required area of ​​metal to be joined, based on its magnetizing properties. This contributes to the formation of a closed electrical circuit, without which manual electric arc welding cannot be performed.

Magnetic welding clamps are used by welders with any experience. Some craftsmen make a special magnetic mass with their own hands. For more details, see our video at the end of the article.

Advantages

Magnetic mass has many advantages. It can quickly be attached to any surface, even curved.

Its design is very simple. It does not deform, so it can be used for years without losing its properties. After all, in essence it is a simple magnet that works thanks to its magnetic field.

Such a terminal does not contain any other devices or parts, and therefore cannot break.

Changes in temperature conditions and voltage surges do not negatively affect the functioning of magnetic clamps. They rarely burn out and can be used in combination with different metals.

They will be especially convenient for cooking in hard-to-reach places or on curved surfaces. The magnetized mass provides a tight fit due to its coverage of a wide surface area.

Source: https://prosvarku.info/prisposobleniya-i-detali/magnitnaya-massa-dlya-svarki