How to cook with flux wire

How to make your own flux for soldering

The flux ensures stable arc burning, promotes the formation of a reliable welded joint, removes unnecessary impurities from the welding zone and generally improves the quality of work. Flux can be bought in the store; modern manufacturers offer a large assortment. But we suggest you make the flux yourself. It won't take much time, but it will save you money.

Mainly, soldering flux is used for welding wires and small parts. There is also a special flux for bga soldering. In this article we will share a "recipe" for making different types of flux or, more simply put, solder, which can be used in most small soldering jobs.

articles

• Varieties
• Instructions for making flux
• Instead of a conclusion

Varieties

Before you start making flux, you need to understand its types and features. To connect two parts, you need to maintain a certain temperature in the welding zone; depending on the metal, it can vary greatly.

In this case, the melting temperature of the solder should be noticeably higher than the melting temperature of the metal you are working with. This leads to the peculiarities of flux selection.

You need to consider the materials you are joining together, their melting point and strength.

Generally speaking, fluxes are hard and soft. Hard fluxes have a high melting point, while soft fluxes have a low melting point. They are also called refractory and low-melting. If the part to be welded is thin, use a soft flux. If it is larger in diameter and requires long-term heating, then use hard refractory solder.

Refractory flux (or solder) melts at a very high temperature (from 400 degrees Celsius) and ensures the formation of a strong connection. But when using such a flux, parts often overheat and may not work. This problem is especially relevant for radio engineers and anyone who is interested in electronics.

Low-melting flux melts at low temperatures and allows it to be used when working with boards and circuits, for example. This flux consists mostly of lead and to a lesser extent of tin. It may additionally contain impurities of other metals. There are separate low-melting fluxes that melt at temperatures up to 150 degrees. They are used when working with transistors.

A high-quality flux should conduct heat unhindered, ensure the strength of the welded joint, have good stretchability, protect the seam from corrosion and be resistant to the melting temperature of the metal.

Manufacturers produce soldering flux in the form of wire, rosin tubes, tapes and many others. Most craftsmen use tin rods with diameters of no more than 5 mm.

There are also so-called multi-channel solders, in which there are several sources of flux. These solders provide a particularly strong connection. They are sold in the form of reels, spirals and skeins. If you will use solder only once, you can purchase a piece of wire, 5 centimeters will be enough for you. For soldering boards and circuits, a flux tube with colophony inside is used.

This solder is perfect for joining silver or brass parts.

Regardless of the type of flux you use, the soldering area after work should be wiped with a rag pre-moistened in acetone. The seam itself can be cleaned using a small stiff brush previously soaked in solvent.

Soldering itself as a method of joining metals has a number of advantages. With it you can achieve a durable and sealed seam that is resistant to corrosion and oxidation. Also, soldering does not require special skills; this work can be performed by a person with minimal theoretical knowledge.

Instructions for making flux

So, how to make soldering flux with your own hands? It all depends on the destination. If you need to solder thin wires, you can use rods with a diameter of 1 mm. We will make them ourselves.

We will need a small bottle or any other vessel with a flat bottom. We make a hole in the bottom with the diameter we need (in this case 1-2 mm). We take lead or tin and melt it using a gas burner. Pour it into our bottle. Molten metal will begin to flow out of the hole; you need to prepare the surface in advance. You can use a sheet of tin, for example. The resulting “rods” must harden, then they need to be cut.

Experienced craftsmen use special molds to make rods.
Also look at the review of bga soldering flux. 
There are also liquid fluxes, fluxes in the form of a gel or paste. They are now very popular and are available from any manufacturer. This is not surprising, because such fluxes do not cause oxidation, prevent the formation of corrosion, do not conduct current, and the soldering area does not need to be cleaned after work. This flux can also be made at home.

We will need rosin crystals, which need to be crushed into powder. Wrap the crystals in a thick cloth and tap them with a hammer (preferably a wood hammer or a meat mallet). Mix the powder and alcohol in a one to one ratio. Alcohol can be purchased at a pharmacy.

It is advisable to mix in a glass container, such as a small jar. Thoroughly mix the alcohol with the powder and place the jar in hot water. Mix everything thoroughly again until it has a homogeneous consistency.

Ready! The resulting flux can be used with a medical syringe or poured into an empty nail polish bottle.

Soldering may release substances that are hazardous to your health. Use protective gloves, a mask and goggles in your work. Do not purchase fluxes from little-known manufacturers, do not chase the lowest price. If possible, make your own flux. Follow safety precautions. This way you will reduce the likelihood of poisoning from flux vapors.

Instead of a conclusion

Now you know how to prepare soldering flux at home. This skill will be needed by both those who rarely use flux and those who use it constantly in their work. You don't need to have special skills or look for rare components. All materials for making flux can be found in a radio engineering store or pharmacy. Describe your flux making experience in the comments to help other beginners, and share this article on your social networks. Good luck!

Source: http://home.nov.ru/kak-svoimi-rukami-prigotovit-flyus-dlya-pajki/

The nuances of semi-automatic welding without gas

A standard semiautomatic welding machine without gas is a type of classic electric arc equipment in which a special welding wire is used as a protective additive.

A wire product filled with flux or powder composition is fed to the processing site (into the welding head) at a constant speed through a special mechanism.

Features of the method

Additives that are used when welding without gas make it possible to reduce the diameter of the wire to 0.8-2 mm, and at low currents to obtain the required degree of metal melting.

Using this method, it is possible to obtain high-quality and reliable seams when fusing products of any thickness, as well as significantly increase the efficiency of the semi-automatic machine.

Semi-automatic welding of metal workpieces without shielding gas provides a number of advantages, the main of which are:

• eliminating the need to carry heavy cylinders;
• significant savings on gas mixtures, the refilling of which costs a lot of money;
• a variety of methods for forming additive compositions (using flux, powder and similar fillers);
• the ability to control the location of the welding cut directly through the mask.

When welding metals semi-automatically without gas mixtures, some professionals manage to produce from 20 to 40 meters of connecting “threads” per hour.

Features of semi-automatic welding include the use of gas-replacing attributes such as wire consumables.

The wire is produced in the form of a thin steel tube, the diameter of which is selected to be about 0.8 mm (similar to welding in a gas environment). Its internal cavities are filled with a special powder flux, its composition reminiscent of the coating of standard electrodes.

During the welding process using a semi-automatic machine and with strong heating, the filling composition completely burns out. As a result, a cloud of gas appears in the resulting bath, which reliably protects against the access of oxygen.

Equipment setup

High-quality preparation for the welding process without gas requires special setup of equipment. According to the requirements of regulatory documentation, for this it will be necessary to set the welding current value on the semiautomatic device corresponding to the thickness of the metal workpieces being fused.

The instructions supplied with the semi-automatic device must indicate the working ratios of these quantities. It is important to take them into account, since if the current value is too low, the quality of workpiece processing may deteriorate, and if the current value is too high, the part can be burned.

Then you need to adjust the t-mode of the wire feed (the speed of its movement is set by a set of several replaceable gears).

It is advisable to test the correct settings of the semi-automatic device and the choice of its operating modes on an unnecessary test product, and make adjustments if necessary.

To weld, set the feed switch knob to the “Forward” position, and then fill the flux funnel.

It is necessary to set the extension of the holder in such a way that the tip is located in the welding zone. Then move the flap of the funnel with flux to the open position and press “Start”, while simultaneously briefly running the electrode over the area to be welded.

Once a stable arc appears, you can proceed directly to the welding process. A semi-automatic device configured according to the recommendations will provide a stable electric arc without gas protection and supply the required portion of flux to the combustion zone.

Welding technique

Before starting welding semi-automatic workpieces without gas (without carbon dioxide, in particular), you should always remember that when fusing vertical seams, vapors of combustible flux rise to the top.

In this case, it is most convenient to start the seam from the top of the workpiece, which is especially important when working with thin metal sheets.

When working with a semi-automatic machine, the torch handle must be held at a slight upward angle, since in this position it will be more convenient to hold the weld pool at the site of its formation.

The burner must move quickly enough along the joint being formed to prevent the formation of drops of molten metal. In this case, the wire itself is always fed to the front edge of the weld pool.

The type of semi-automatic welding under consideration without gas is somewhat reminiscent of working with a conventional electrode, during which slag sometimes flows into the molten pool.

By analogy, in this case, welders often have to make another one on top of the resulting seam, but only after the previous one has been cleared of slag.

The flux-cored wire used for welding without gas is soft enough, so that sharp bends in the hose are not allowed when handling and working with it.

When welding semi-automatically without gas, it is strictly prohibited to use ordinary wire, as this can lead to the formation of a poor-quality seam (with irregularities and voids). In addition, there will be an overexpenditure associated with the useless evaporation of the protective coating.

Working with a welding inverter

The inverter method of welding without gases differs from the generally accepted method only in some details. When implementing it, the most important thing is to correctly set the welding current and select an electrode that corresponds to the welding conditions (the optimal size is 25 mm).

As when working with a semi-automatic machine, the current is selected taking into account the thickness of the material being processed, and the electrode is brought to the junction of the metals very smoothly. The last requirement eliminates the possibility of it sticking and overloading the unit.

To ignite the arc, the electrode is positioned at a slight angle relative to the surface being treated, and then lightly touches it, followed by tearing it off. After the arc appears, the electrode should be kept at a certain distance from the welding line, approximately equal to its diameter.

From the description it follows that welding with an inverter without shielding gas cannot be called original, but in this case the size of the arc gap formed between the electrode and the metal is very important.

If it is not possible to maintain the required gap, even in the presence of flux, the seam still turns out to be too convex (at the fusion sites the metal does not have time to warm up). If the gap is too large, an unstable arc may occur, which also affects the quality of the seam (it may turn out uneven).

To an even greater extent, the quality of welding without gas depends on the correctly chosen polarity of connecting the supply wires, which, when working with an inverter, are connected with the minus to the holder, and with the plus (ground) directly to the workpiece. This connection is usually called “direct”.

When working with a semi-automatic machine or inverter, it is important to organize the welder’s workplace, within which the equipment and all auxiliary devices for welding without gas are located.

First of all, you need to worry about creating a ten-meter protective zone formed around the workplace and preventing outsiders from entering it. In addition, special measures should be taken to remove explosive and flammable substances from this area.

Source: https://svaring.com/welding/apparaty/svarka-poluavtomatom-bez-gaza

How to cook stainless steel semi-automatically

Unlike ordinary steel, not every craftsman can perform high-quality semi-automatic welding of stainless steel. To obtain a reliable connection, it is necessary to take into account its features, correctly set the operating mode parameters and select consumables. The success of the work largely depends on the quality of the equipment.

Features of stainless steel welding

Alloying additives make stainless steel resistant to corrosion and acids, but at the same time it acquires properties that make welding difficult. Compared to conventional steel, thermal conductivity is reduced by half. This makes it difficult to remove heat from the welding site, which leads to overheating of the metal, burn-through and burnout of chrome. To prevent this phenomenon, welding is performed with a current 15 - 20% less than the standard one with additional cooling of the workpieces.

Stainless steel has a high coefficient of thermal expansion, which leads to cracking of the seam and the metal next to it. To neutralize it, a large gap is left between the workpieces. Due to the high electrical resistance of the material, the electrodes for welding stainless steel overheat, which does not have the best effect on the quality of the seam. Therefore, they are cut to the minimum possible size so that they do not have time to heat up.

Having learned about the difficulties, beginners ask the question: “Is it possible to weld stainless steel semi-automatically at home?” The answer, of course, is yes. Three methods are used to connect workpieces:

• short arc;
• impulse method;
• jet transfer.

Thin stainless steel is welded with a short arc, as it reduces the likelihood of burning through. The jet transfer method is used to join thick-walled parts made of stainless alloys in production. Welding is carried out using flux-cored wire and special heads.

To create a protective environment during pulse welding, a mixture of argon and carbon dioxide is used. The advantages of the method include:

• the ability to connect both thin and thick workpieces;
• feeding the wire in short pulses prevents splashing of molten metal;
• saving of filler material;
• excellent connection quality;
• high performance.

Selection of materials for welding

To obtain a high-quality weld, the composition of the filler wire must be the same as that of the metal being welded. It is better if the content of alloying elements is slightly higher. If you use regular brands, the connection will quickly rust. For welding stainless steel alloyed with chromium, flux-cored and wire with a high nickel content are produced.

Source: https://svarkaprosto.ru/tehnologii/kak-varit-nerzhavejku-poluavtomatom

Flux Welding Wire

The welding process requires not only the correct selection of consumables, which includes various types of welding wire, but also the necessary modes of the procedure, protective equipment, and so on.

One of the frequently used consumables is flux. It performs protective functions and also improves the weldability of metals. Its use is almost always desirable, especially if it is selected accordingly.

To simplify the selection and use procedure, flux-cored welding wire is produced.

Flux Welding Wire

This option already contains flux, which is perfectly suited to the wire material itself and the purpose for which it is used. It is worth noting that similar varieties are available in almost all types of wire, no matter what metal it is used for.

Such brands perform best in automatic welding, but are used equally well in semi-automatic and manual mode. Here you do not need to choose the proportions of addition, perform any preparatory procedures, etc., since everything is immediately ready for use.

This filler material is suitable for both beginners and professionals.

Flux Welding Wire

Naturally, welding wire with flux will cost more than ordinary wire. But the fact that additional materials do not need to be purchased and use becomes more convenient completely overcomes these shortcomings.

Often, flux-cored welding wire is somewhat thicker due to the content of additional substances inside. Its design assumes the presence of a rod inside, which consists of flux.

Thus, it can be bent, a part can be cut off, and other procedures can be performed, but the substance to improve welding will always be present, and in the same proportion.

The most widely used welding wire with flux is found in industry, joining metal structures, in automatic devices, and so on. Many experts rely on it when choosing high-quality metal processing for critical repairs. For a product to truly meet its stated quality, it must meet accepted standards. Flux-cored welding wire is produced in accordance with GOST 26271-84.

Advantages

• No additional use of flux or its calculation in a certain proportion is required;
• The welding process becomes better and the percentage of defects decreases;
• The use of wire becomes simpler and more efficient;
• Many negative nuances of difficult-to-weld metals fade into the background thanks to correctly selected additional consumables;
• The connection speeds up, since welding with flux-cored wire allows it to come into contact with the base metal faster;
• For automatic devices, this is one of the best options, which guarantees a more reliable connection;
• There is no risk that any extra elements will get into the molten seam with the flux.

Flaws

• The welding wire for submerged arc welding has a relatively high cost, so the cost of the joining process is not always profitable;
• Such varieties are not as common as standard ones;
• In some cases, the problem of poor weldability cannot be solved and additional means are still required;
• The thickness of such material is higher, which complicates the selection of the required diameter for the selected operating mode.

Physicochemical characteristics

Flux-cored welding wire for semi-automatic machines has good ductility and interacts well with the feed system on the machine. At the same time, the material has greater wear resistance, which makes it easier to move, store and contact with other surfaces.

This is done to protect the flux layer from damage. Automatic submerged arc welding welding wire has a lower melting point than the base metal.

The properties of the steel material make it possible to work with both low-carbon and high-carbon workpieces.

Flux Welding Wire

Improved welding properties due to selected soft metals and the presence of additional elements ensure stable arc burning when using argon arc welding. The material contains a minimal amount of hydrogen and other substances that negatively affect the condition of the seam and can cause cracks, pores and other defective elements. This results in the formation of a relatively small slag crust on the surface, so that it can be removed without problems.

Varieties

Submerged arc welding wire varies in diameter and in the base metal to which the welding will be carried out. This determines which flux will be used:

• For steel - the material is divided depending on the level of alloying, as it can be used for high-alloy steels to replace those elements that are lost during heat treatment. This also applies to stainless steel welding.
• For copper - 08 mm flux welding wire, which is designed to work with copper parts, helps improve the connection of this refractory metal at normal temperatures.
• For aluminum - when welding aluminum, flux is required, so this product will be an excellent option to do everything with the highest quality and reduce the likelihood of defects.

Specifications

Parameter	Tensile strength, (MPa)	Yield strength, (MPa)	Relative elongation, %	Impact, KV cut	What gas can be used for protection?
0, degrees Celsius	-20, degrees Celsius
Minimum value	480	400	22	47	27	CO2
Maximum value	580	490	27	120	103

Features of choice

Flux-cored welding wire 0.8 mm is used for the thinnest parts. For other procedures, 2 mm is suitable if the metal thickness is 2-4 mm. Thicker versions up to 6 mm are often used for production.

When choosing, you need to pay attention not only to the diameter, but also to the composition, since this is a more important parameter. It should be as similar as possible to the base metal. There is no need to select flux, since everything is already determined automatically by the manufacturer.

For private use in small volumes, it is better to buy welding wire for semi-automatic machines with flux in cassettes, and for large-scale work - in coils.

"Important!

There is flux-cored wire for welding without gas, as one of the most richly supplied with additional substances option, but for critical connections it is still better to use it in a protective gas environment or use another option.”

Welding Features

The main feature of flux-cored wire welding is the absence of lengthy preparations.

The only thing that will have to be done here is to bevel the edges of the joint if the metal thickness is more than 4 mm, and also treat it with solutions if the metal is prone to forming an oxide film.

Wire for automatic submerged arc welding, as well as its other varieties, has everything necessary to ensure a high-quality connection in the area for which it is used.

The main thing here is to set the feed speed correctly, since due to the presence of additional materials, the melting temperature can be noticeably lower than that of flux-free analogues and the base metal. This is well manifested due to the fact that the wire begins to melt without any problems, even when working with small thicknesses, it does not lead to burning of the metal.

Manufacturers and popular brands

Source: https://svarkaipayka.ru/material/svarochnaya-provoloka/flyusovaya.html

Semi-automatic welding without external gas supply, submerged arc: what is it suitable for? Welding technique

When describing the method, the phrase “without gas” will be inaccurate. More correctly, without external gas supply, because it is still involved: the welding wire is a tube with a diameter of 0.8-1 mm, filled with powdered flux, the composition of which is similar to the coating of the electrodes. During the process, the powder burns, forming a protective gas environment in the weld area.

Factors that affect the quality of the connection are current strength and wire feed speed. The first indicator is set depending on the thickness of the parts; the speed is uniform and sufficient to obtain a high-quality seam.

Semi-automatic welding is used to connect products made of aluminum, low-alloy and corrosion-resistant metals with a thickness of 1.5 to 10 mm.

State standards of technical process and equipment used

The technology and process parameters are regulated by the USSR state standard of 1977, extended in 1991, GOST 11533-75 “Automatic and semi-automatic submerged arc welding. Welded joints at acute and obtuse angles.” GOST introduces designations for subtypes of the method:

• Ac – automatic submerged arc welding on a steel backing;
• Apsh – automatic submerged arc welding with preliminary application of a backing seam;
• P – semi-automatic submerged arc welding;
• PS – semi-automatic submerged arc welding on a steel backing;
• PPsh – semi-automatic submerged arc welding with preliminary application of a backing seam.

The necessary parameters of the equipment are contained in GOST 18130-79 “Semi-automatic machines for consumable electrode arc welding”, created in 1980, extended in 2015. It contains requirements for rated voltage, electrical circuits, total cable cross-section, operating conditions and other process characteristics.

Features of the semi-automatic method

Due to their compactness, semi-automatic devices work in hard-to-reach places: on high-rise structures, in tight spaces and tunnels.

Unlike the method using gas-cylinder equipment, the semi-automatic method uses a direct connection: “minus” is applied to the electrode, and “plus” is applied to the workpiece. This creates a temperature sufficient to burn the flux powder and create a protective environment.

Pressure rollers are installed in accordance with the diameter of the wire. The roller itself indicates the range of diameters that can be used. Do not apply too much force when tightening the roller, this can lead to compression of the hollow wire inside and a blockage in the cable channel.

Design and principle of operation of the device, types of wire

Installation equipment:

• welding torch gun;
• control unit;
• mechanical wire feed unit;
• flexible hoses;
• bobbin with wire;
• electrode supply pipeline;
• electric wires.

Electric current is supplied to the connection area, the arc melts the electrode, and the flux, evaporating, protects the weld pool from oxygen. The electrode is supplied automatically, the burner is moved manually.

Inverter semi-automatic welding machines are more productive and ergonomic, and the arc is ignited faster.

Approximate cost of welding machines on Yandex.market

Welding wire varies in cross-section:

• circular;
• double-cavity with a bend , type Ɵ;
• double-cavity with two bends;
• two-layer (circle within a circle).

Semi-automatic welding scheme without gas

Semi-automatic operating technique without gas

Before starting work, prepare the surfaces to be fused: clean the seam area with a grinding machine, then degrease the welding area. Manufacturers attach tables for selecting current strength on installations depending on the thickness of the workpiece. After determining the desired current indicator:

• replaceable gears regulate the wire feed speed so that it does not slip, but is not pressed tightly;
• to select a stable arc value, boil a small test area;
• set the electrode supply switch to the “forward” position , strike with the tip, and after the arc appears, make a seam;
• control the smoothness of the process.

Advantages and disadvantages of the semi-automatic method of working without gas

The advantages include:

• mobility (no heavy gas equipment);
• ability to continuously weld extended joint sections;
• efficiency of visual inspection of seam quality;
• process speed;
• connecting structures in hard-to-reach places;
• productivity due to process continuity.

Disadvantages:

• high cost of work;
• need for equipment , complexity of setup;
• the complexity of cleaning seams due to the thick layer of slag;
• difficulty working with parts less than 2 mm thick.

Due to the availability and ease of operation of the equipment, semi-automatic welding without gas is used in households, garages and workshops for minor work and repairs.

Source: https://elsvarkin.ru/texnologiya/vidy/svarka-poluavtomatom/

Welding aluminum semi-automatically without gas

Even children know that aluminum is usually welded with a tungsten electrode in an argon environment (TIG welding). But not everyone knows that lumina can be welded semi-automatically. For such a process, you need a powerful semi-automatic machine, with the same broach.

My homemade product fits all the parameters www.drive2.ru/l/288230376152884642/.

By the way, this unit has been working in my workshop for five years without a single serious breakdown, every day, for the benefit of clients’ cars, sometimes destroying 5 kg of wire in 2 days :)

Also desirable is a Teflon insert in the sleeve, sold in welding shops, although I work without problems without it. We take the tip for aluminum 0.2 mm larger than the diameter of the wire. If the wire is 0.8 mm then the tip should be 1 mm, if the wire is 1 mm then the tip should be 1.2, etc.

Or buy a special tip for aluminum wire. The shielding gas for our type of welding will not be carbon dioxide or a mixture, but pure argon. Well, as you understand, the wire itself should also be made of aluminum, although I have seen attempts by “craftsmen” to weld aluminum with ordinary steel SV08G2S :).

Semi-automatic welding, of course, does not reach the level of TIGa jewelry, but in terms of productivity it is far superior.
When you need to melt something, or weld a gap, then the semi-automatic is in the lead by a margin. Due to its high productivity, factories use MIG. For example, repairing a valve cover from a VAZ 2105, which I first damaged with a hammer especially for this entry, took no more than 3 minutes.

https://www.youtube.com/watch?v=vM06YYQQYT8

An oxide film always forms on the surface of aluminum; it must be removed, otherwise it will be extremely difficult to weld the metal, and the resulting part will be of poor quality.

Most often, a semi-automatic machine is used when you need to weld something or close a gap.

Aluminum has high thermal conductivity, and you need to work with it at low temperatures.

Preparing material for welding

Before the process you need to do the following:

• sand the surface;
• remove plaque and oxide film : with brushes, special machines or fluxes;
• degrease the surface with acetone;
• embroider the edges (if the thickness of the workpiece is more than 5 mm);
• cut the edges of the parts at an angle of 30-45 degrees and treat them with flux;
• To prevent parts from deforming, they need to be preheated.

Semi-automatic aluminum welding technology

The following conditions are met:

1. The wire must be fed smoothly , always ahead of the torch.
2. Always move the torch along the seam.
3. Operating speed is maximum.
4. If thin metal plates are used during work, you need to place stainless steel under it so as not to burn it.
5. It is important to take into account metal shrinkage : its expansion coefficient is higher than that of others.
6. It is necessary to set the parameters of the apparatus and the feed rate of the filler material as accurately as possible .
7. Use shielding gas - argon or a mixture of argon and helium.
8. After work, wait until the metal cools down and check the quality of the connection using kerosene.
9. Process the seam and give it an aesthetic appearance.

Source: https://MyTooling.ru/instrumenty/svarka-aljuminija-poluavtomatom-bez-gaza

Flux-cored wire for semi-automatic machines - mobility and quality of connections

Very often, semi-automatic welding has to be carried out in places with difficult access. It is difficult or even impossible to use a gas cylinder in them. A way out that allows you to maintain the advantages of a semi-automatic welding machine, but at the same time abandon the bulky cylinder, is to use flux-cored wire for a semi-automatic welding machine.

Classification and labeling

All modern flux-cored wire, both domestic and imported, is divided into types according to seven characteristics:

1. The purpose of the resulting connection.
2. Strength characteristics of the seam (tear resistance and impact strength).
3. Composition of the inner core.
4. The type of protective coating formed during the welding process.
5. The position in space of the parts being welded in relation to the electrode (options are possible here - only vertically, only horizontally, only in the lower horizontal plane, only in the lower vertical plane, in any position).
6. The metals being connected can be steel (alloyed or not), non-ferrous metals, alloys.
7. The ability to form external gas protection or not (in the latter case, a carbon dioxide cylinder is needed).

In Russia, according to a number of sources, the most popular and widespread brands are:

• ER70S-6;
• E71T-1;
• E71T-GS;
• T-8;
• T-GS;
• BlueWeld 802208;
• Forte.

If you need to connect metal made no thicker than 2 mm, 0.8 mm wire In the case where the thickness of the part is greater, but does not exceed 5 mm , use 2 mm in diameter. For really massive parts to be connected, you need to use a diameter of about 6-8 mm or more.

Depending on the material of the parts to be joined by welding, three types of wire can be distinguished:

1. For welding aluminum parts. When working with this material, it is impossible to do without flux.
2. For welding copper parts. The most common is 0.8 mm in diameter.
3. For steel products. Involves preliminary preparation of the connection site.

Main characteristics

Flux-cored wire in standard (compliance with GOST) has excellent quality and ease of welding other metals. The seam formed by it contains a minimum of impurities that worsen its mechanical and chemical properties. The weld is usually strong, minimally slagged, and resistant to corrosion.

The process of welding thick parts (more than 5 mm) is complicated by the need to select the correct electrode and operating mode of the device.

As the name suggests, flux-cored wire already contains flux, so when working with it there is no need to calculate the exact amounts of additives. In addition, the finished mixture is less toxic and more homogeneous than one compiled by the welder himself.

According to its design, flux-cored wire consists of two parts:

• Outer shell - it is a spiral-curled tape of unalloyed steel with a thickness of 0.2 to 0.8 mm . The shell protects the core.

• The core consists of a compressed powder of complex composition. It most often includes substances that deoxidize the metal melt, stabilize the electric arc, and alloy the resulting seam.

Welding with flux-cored wire without gas

Before you start the welding process, you need to set the recommended current values ​​on the machine. Next, you need to check the condition of the feed sleeve (for wear) and the absence of movement of the feeder. The feed rollers also need to be calibrated - they should not press too hard to avoid deformation and uneven feeding.

https://www.youtube.com/watch?v=zWCxmT1NA0c

The parts to be joined must be cleaned of the oxide film and, if the thickness is more than 4-5 mm , bevels must be formed. After the electric arc occurs, it is conducted from the bottom to the top of the part (if it is located vertically). The torch handle should be held at an angle to the surfaces being welded - this stabilizes the weld pool and protects against premature spreading of metal from it.

It is recommended to keep the seam removal speed at about 15-20 mm per second. When forming a seam in several passes, you need to wait for the layer to cool and clean its surface from the slag crust - otherwise the second and subsequent seams will turn out to be of poor quality due to foreign impurities.

Is it better to weld with an electrode or a wire?

What are manual arc and semi-automatic welding, and what are their main differences from each other?

Manual arc welding uses both consumable and non-consumable electrodes. During work, the welder melts metal with an electric arc. This process ensures the mixing of the molten material that makes up the workpiece and the electrode.

The quality of the resulting seam is determined by the chemical composition of the joint and the weldability index. It is also important to consider the diameter, chemical composition and type of electrode used.

Manual welding also involves choosing the optimal mode, which depends on the length of the welding arc and the current density and its strength.

The manual welding method is determined by the thickness of the metal and the expected length of the seam. Thick metal sheets are welded in several passes, and thin pieces can be overlapped. Separate manual top and bottom welding.

The main difference between semi-automatic welding and manual welding is the use not of electrodes, but of flux-cored wire, fed automatically during the welding process using a reel. The welding process itself is carried out manually by the worker. This allows you to get all the advantages of the manual method and at the same time increase labor efficiency.

While operating the semi-automatic machine, there is no need to take breaks to replace the electrode. Semi-automatic welding can take place in a shielding gas environment. You can also use self-shielding wire.

Which welding is better

It is incorrect to say that semi-automatic welding is better than electric arc welding or vice versa. Each option has its own advantages and disadvantages that need to be considered before choosing a specific type of welding.

Pros and cons of manual arc welding

Advantages:

1. Ease of operation and maintenance of equipment . Almost every person can master the basics of arc welding.
2. Such welding can be carried out in different positions : both from below and from above, and at an angle and from the side.
3. Thanks to the possibility of using a bent electrode, the seam can be laid in hard-to-reach areas of the product.
4. The manual welding method allows you to work with a large number of metals.

Flaws:

1. Electromagnetic radiation emitted during work is harmful to the health of the worker.
2. The quality of seams depends, first of all, on the skills of the welder..
3. Compared to other options, arc welding does not have the same efficiency and productivity.

Pros and cons of semi-automatic welding

Advantages:

1. You can even work with metal products that are slightly corroded.
2. The connection process does not require significant costs for consumables.
3. The range of applications for semi-automatic machines is quite high ; they can be used for welding thin steel sheets up to 0.5 mm thick.
4. Copper alloy wire can be used.
5. During operation, the liquid metal is reliably protected from exposure to air.
6. Oxide and slag do not appear on the seams.
7. The connection is created faster than with manual welding.

Flaws:

1. If there is no protective gas jet, the metal from the weld pool may splash heavily.
2. Semi-automatic welding creates a brighter electric arc , so the issue of eye protection must be taken seriously.

Areas and features of application

The manual electric arc method is mainly used for the following activities:

1. Connecting parts and reinforcing mesh.
2. Construction of durable reinforcement frames and meshes.
3. Connecting rods and installing reinforced concrete structures.
4. Preparation of fittings , if there is no special connecting equipment.

Semi-automatic welding is used:

1. In mechanical engineering, aviation, oil refining industries.
2. For joining non-ferrous metals.
3. When working with metals with high melting points.
4. For the production of pipes with both straight and spiral seams.
5. For joining high-alloy alloys like stainless steels.

Most often, semi-automatic machines are used when welding black steel and aluminum is necessary. Carbon dioxide is used as a protective jet, since it is quite cheap. Helium and argon can also be used.

Source: https://rem-serv.com/chem-luchshe-varit-elektrodom-ili-provolokoy/

Semi-automatic welding without gas using regular wire – Chief mechanic

Welding is becoming more and more popular among professionals, amateurs and beginners who prefer to start learning how to make their first welds using high-quality equipment. This is due to a number of advantages of hardware welding to manual welding with coated electrodes:

• versatility - semi-automatic machines are capable of welding structural steel, stainless steel and other metals such as cast iron, aluminum, copper and their alloys;
• simplicity of the process - anyone, even those who have picked up a holder for the first time, can, after a short time, learn how to make seams of sufficiently high quality;
• possibility of permanent connection of thin metal. High speed and productivity.
• convenience - you do not need to change the position of your hand during the process as with the electrode.

The connection of parts is divided into two types: with shielding gas and without shielding gas.

Semi-automatic welding with flux-cored wire without gas

Flux rod is a hollow tube filled with flux powder, which, when burned, provides the necessary gas protection against the oxidative effects of oxygen, forming a cloud of protection in the arc combustion zone. wire rod with flux allows you to work without the use of protective gas.

Advantages:

• There is no need to carry a gas cylinder with you; a small device is enough.
• semi-automatic welding without gas is much cheaper, especially if on-site repairs are required.

The disadvantages include:

• high cost of wire;
• insufficient quality, domestic manufacturers, imported ones will cost more, when purchasing you need to carefully inspect the products, because the wire does not always meet the required parameters. Because of this, the work process may not take place.

Types of wire for manual semi-automatic machines

Welding rod for manual semi-automatic machines is supplied in the form of coils or rolls weighing from 2 to 5 kg. Main diameter 0.6,0.8,1,1.2 mm. diameters greater than 1 mm are used in industrial devices.

To prevent external influences, products are packaged in dense materials that do not allow air to pass through, resulting in condensation forming inside. To avoid this phenomenon, the product must be dried for several hours at 200°C before use.

Powder

Flux-cored wire is a hollow steel shell filled with flux powder, which, when burned in an electric arc, forms a protective cloud in the welding zone, protecting it from the harmful effects of oxygen. Active additives in the flux prevent the formation of slag on the weld seam.

You can buy wire for semi-automatic welding without gas on specialized Internet resources or dealerships selling welding equipment.

Copper-plated

The steel rod is intended for permanent connection and surfacing of carbon steels. the rod is coated with a special copper composition using an electrochemical method to prevent surface corrosion of the metal. The product is produced with a stable chemical composition and has a low price. Semi-automatic welding without gas with ordinary wire turns out to be of poor quality: the seam is uneven with a large number of cavities and slag inclusions.

Alloyed

A product is produced with additives, highly alloyed components, which include nickel, tungsten, and copper. Welding seams are highly durable. Low alloy has a minimum volume of filler components.

Stainless steel

For permanent connections of parts made of stainless components, suitable wire made of stainless metal is used. High-quality wire has alloyed additives such as manganese, phosphorus and chromium. Depending on the filler element, the wire can be hard, soft, and heat-resistant.

The material is quite expensive, so setting up a semi-automatic device must be as precise as possible. Using semi-automatic welding without gas using ordinary wire will not give results, because...

the welding seam will end up with large pores and due to the connection of different metals with mechanical properties, mechanical stresses will arise between the plates, which will lead to cracks.

Aluminum

This type of product is intended for permanent connection of parts made of aluminum and its alloys. The product is based on aluminum with the addition of various additives that improve the quality of the weld.

One of the features of the use of this product is that the wire must be used within several days after opening the package, since prolonged exposure to air contributes to the formation of an oxidizing film. To reduce the influence of oxide on the seam, the semi-automatic machine is set to alternating current mode.

Welding aluminum semi-automatically without gas is rarely used due to the poor quality of the weld. The most common practice is to connect aluminum parts in a protective gas environment - argon.

Table of technical characteristics of wire for aluminum parts

Base metal to be welded Filler material (welding wire) universal Filler material (welding wire) special to ensure special properties of the weld

Resistance to hot cracks	Tensile strength	Relative extension	Corrosion resistance
A99, A97, A95	A99	A99	SvA85T	A99	A99
AD0, AD1	SvA5	SvA5	SvA5	SvA97	SvA97
Amts	SwAMts	SwAMts	SwAMts	SwAMts	SwAMts
AMg3	SvAMg3	SvAMg5	SvAMg5	Avch	Avch
AMg5	SvAMg5	SvAMg6z	SvAMg6	SvAMg5	Sv1557
AMg6	SvAMg6	SvAMg6z	SvAMg6	SvAMg6z	Sv1557
AB, AD31, AD33	SvAK5	SvAK5	Sv1557	Sv1557	Avch
1915	Sv1557	SvAMg5	SvAMg6	SvAMg5	Sv1557

Preparing for work

One of the features of welding without gas supply is the reverse polarity of the current source. When setting the wire feed, you must make sure that the diameter of the feed socket in the feed roller matches the diameter of the wire.

The pressure roller does not need to be tightly tightened, since the soft shell may become wrinkled; to prevent this from happening, when feeding, the torch tip must be screwed to the body only after the end of the wire rod appears from the channel hole. Only after this should the tip be installed.

There is no need to adjust the nozzle in this way - as during operation there will be no gas flow through it.

Equipment for work

To get started, you need a welding wire feeder and a power source, welding wire and shielding gas (when working in a shielding gas environment). The gas used is carbon dioxide CO2, or a mixture of carbon dioxide and argon, the standard mixture is 80% argon and 20% carbon dioxide.

First, you need to decide on the operating conditions of the device: how many hours it will be in continuous operation, what thickness of metal will be welded. So, for example, if the metal thickness is 5 - 10 mm, then the required current of the semi-automatic device should be approximately 50 - 400A.

If the device is intended for permanent connection of automotive iron with a thickness of 0.8-0.6 mm, a power of up to 200 A is sufficient. It is also necessary to determine how long the continuous operation will last. If this time exceeds more than 4 hours.

Then it is necessary to choose a device with a payload of more than 60%.

We present one of the popular semi-automatic welding machines Solaris MULTIMIG-228

The device operates in 3 modes:

The device has a wide range of functions, which will find wide application in service stations, repair shops, as well as in private households. The heart of the device is a microprocessor system that performs functions to control the device components. This control of the device is the most optimal in all operating modes. The plastic elements of the body are made of high-strength polyamide.

The front panel is equipped with two digital displays displaying welding current and welding voltage. This allows you to control the parameter settings as accurately as possible during operation. On the display, the device reflects the actual voltage and currents used for this type of work, allowing you to set a more optimal operating mode.

The device is lightweight, with small dimensions. The device will allow you to quickly learn semi-automatic welding techniques for beginners without gas and in other modes. You can also find training material on Internet resources; semi-automatic welding without gas, a training video can be viewed here.

You can buy semi-automatic welding without gas on specialized Internet resources or at specialized dealer centers, where you can get qualified advice when purchasing equipment for semi-automatic welding without gas at discounted prices.

Source: http://themechanic.ru/svarka-bez-gaza

How to cook semi-automatically with flux wire

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Very often, semi-automatic welding has to be carried out in places with difficult access. It is difficult or even impossible to use a gas cylinder in them. A way out that allows you to maintain the advantages of a semi-automatic welding machine, but at the same time abandon the bulky cylinder, is to use flux-cored wire for a semi-automatic welding machine.

Do-it-yourself flux for welding aluminum

The process of welding aluminum is very labor-intensive. This is due to the characteristics of the non-ferrous metal. Special modes are being developed to reliably fasten aluminum products and its mixtures. Let's look at the question of how to cook aluminum.

Area of ​​use

Aluminum is a non-magnetic material, so its mixtures have unusual characteristics: light weight of parts, high conductivity of energy of any type, resistance to mechanical stress.

Aluminum alloys are used in welding devices for various purposes, as they have a lot of useful qualities: low density, increased resistance to corrosion processes and high specific strength.

Non-ferrous metal in its pure form is very fragile, so it is used only in certain sectors of industry. It is known to be widely used as semiconductors.

Features of welding aluminum parts

Welding aluminum is difficult due to its characteristics. Main features of aluminum welding:

• There is always an oxide shell on the surface layer of the metal. The melting point of the oxide is 2037 degrees, and the colored element itself is three times less, about 660 degrees Celsius.
• The metal is easily oxidized, so to weld it you need to protect the work area from harmful exposure to air.
• Spreads abundantly in the work area. Therefore, there is a need to use pads that remove heat from the area being welded.
• The seam is not always strong, as cracks and pores may appear in it. The formation of pores in the metal is facilitated by the gas that is dissolved in it, and it tends to escape into the atmosphere. The appearance of cracks is inherent in aluminum alloys, due to the high silicon content when the metal is cooled.
• Tendency to significant shrinkage.
• Due to the excessive thermal conductivity of the metal element, it becomes necessary to use an increased welding current.

The main features of aluminum welding are given, but there are many more. Therefore, metal is considered a capricious element and brewing it is a problematic matter.

Welding methods for aluminum parts

To carry out the process, different methods of aluminum welding are provided, for example, the use of various compositions and devices, special elements for enclosing the welding area.

By special means, as a rule, we mean fluxes and inactive gases. Flux is a powdery substance, diluted with water to obtain a state resembling sour cream, and spread onto the twists with a brush or by dipping.

The powder is able to rid the metal of the oxide layer and prevent sticking of the carbon electrode.

The most popular options for welding aluminum at home and in production conditions are:

• welding of aluminum with an electrode using a sphere of inactive gases (AC TIG method);
• semi-automatic welding of metal in the field of inert gaseous substances with automatic supply of filler rod (DC MIG - aluminum welding technology);
• the use of fusible electrodes surrounded by a flux shell without gas and the use of gaseous substances (MMA option)

The main condition for cooking a colored element and its mixtures is the need to remove the film layer from its metal surface. To destroy the layer, you need alternating or direct current, but of reverse polarity. As a result, cathode sputtering is carried out, and the oxide shell is destroyed.

The process of welding aluminum parts at home

Situations arise when there is an urgent need to join difficult-to-weld metals at home and therefore a logical question arises, how to weld aluminum at home or simply how to weld in general? A person often has to deal with them, since many household supplies are made of aluminum or its mixtures.

But one problem arises: it is difficult to create the necessary conditions so that welding with aluminum electrodes is similar to that at a production facility. Therefore, the quality of the connection may suffer. Usually, primitive welding of metal is carried out at home, that is, welding aluminum at home with an inverter.

The device is used for argon arc cooking.

Welding aluminum at home is characterized by a number of useful indicators:

• Cost savings, especially if appropriate equipment is available;
• Instant results. The quality of the seam is determined immediately;
• The use of improvised elements.

Defects in welding parts in the home environment. Among the shortcomings of the work are:

• low quality seam;
• difficulty in selecting available materials;
• difficulties in maintaining personal safety when working with gaseous substances;
• there are no necessary conditions for storing electrodes for aluminum welding.

Preparing metal surfaces for welding

Preparing aluminum for welding involves a number of operations:

• Chemical treatment. It is necessary to clean the working metal surfaces from contamination, in the form of grease and oil deposits. Technical solvents, such as acetone or white spirit, are used to degrease parts. In addition to solvents, etching in alkaline baths is widely used. The alkali rate is 50 g/l, exposure time is 60-90 seconds. After alkaline treatment, the parts are washed with water. This is followed by a clarification operation; for this, the workpiece is kept in a solution of nitric acid for up to 2 minutes. This is followed by washing again and blowing with hot air.
• Mechanical cleaning of workpiece surfaces (edges). For this operation, you will need a grinding machine with a steel wire brush attachment or a regular file. After such cleaning, the surface is degreased with a technical solvent.

Manual electric arc welding with specially coated electrodes (MMA technology)

Electric arc welding of aluminum is used to create conventional (non-critical) structures with a metal thickness of at least 4 mm. This welding method has a number of disadvantages: low-quality weld, excessive spattering of metal during operation, low slag separation, which may result in a rusting process.

Electrodes with special coatings are used to weld both pure non-ferrous metal and its mixtures, for example, duralumin. Currently, electrodes of the UANA and OZANA brands are produced, replacing the outdated OZA models.

The connection of lightweight metal surfaces is carried out using direct current with reverse polarity. A current of 25 amperes is received per 1 mm of electrode.

To create a high-quality metal seam, it is heated to 350-400 degrees Celsius. Thus, welding of duralumin is carried out with preheating of the part to 300 degrees Celsius. This heating and subsequent cooling operation are done in order to get rid of the possibility of crystallization cracks appearing, as well as to reduce the deformation of the material. For welding volumetric products, it is advisable to use local heating of the working area.

Upon completion of the work, you should get rid of unnecessary residue from the seam. To do this, the metal surface should be washed with hot water and treated with a metal brush.

Welding with a non-consumable electrode in argon (AC TIG method)

Electrode welding is the most popular procedure as it is used to create structural shapes. Consumable items are subject to special requirements in terms of strength components.

The electrodes for welding aluminum are special here - tungsten rods of 1.6 - 5 mm are used, which can withstand temperatures of 3 thousand degrees Celsius, and filler wire with a diameter of 1.6 - 4 mm. These tungsten rods are almost never consumed, since they only take part in generating the electric arc.

The filler element is an aluminum rod. Shielding gases are helium or argon with a high level of purity.

The arc is powered from an alternating current source capable of efficiently removing the oxide shell. The main parameters, namely the diameter of the electrode and rod, the numerical value of the welding current - all depend on the equipment used.

The parameters of the welding area should be at a minimum level. The speed of the electrode welding process on aluminum depends on the flow rate of inactive gas.

If gas is used in excessive quantities, it leads to undesirable consequences, namely air entering the work area.

It is worth noting that the gas (argon) is supplied 4 seconds before the arc ignites, and is turned off 7 seconds after its destruction.

Semi-automatic aluminum welding (DC MIG technology)

Pulse equipment is considered the most effective way to weld lightweight metal, as it is more productive. The resulting high voltage surge quickly destroys the oxide shell, then it instantly tends to the base value. Each particle of the molten metal rod (electrode) is driven into the welding zone. Thanks to this “filling”, a high-quality seam is created. This is how spot welding of aluminum is obtained.

Such equipment is not cheap. Some craftsmen have learned to modify standard semi-automatic machines for welding aluminum surfaces, and now they can easily work with aluminum with minor modifications.

According to the principle of operation, the technology of welding with a semi-automatic device does not differ from the standard mode of steel welding. But there are some technical aspects:

• It is unacceptable to cook aluminum and mixtures with current with direct polarity, only the opposite option.
• Aluminum rod is softer than steel rod, which can create loops. To eliminate this, you need to get a special feeder with 4 rollers, a small sleeve and a Teflon liner.
• When heated, non-ferrous metal expands more than steel, so a situation may arise where the wire gets stuck in the tip of the feeder. To avoid such incidents, you need to use special tips marked Al or standard models, but with an increased diameter.
• By comparing the welding wire made of aluminum and steel, the non-ferrous metal rod melts more intensely. Therefore, an accelerated feed rate should be ensured. Otherwise, frequent tip replacement is necessary.

  Do-it-yourself resistance welding from an old TV

Special materials, tools and practical recommendations

The process of joining parts requires certain skills and depends on the selected welding method. Among the tools necessary for optimal operation of aluminum welding at home are:

• Welding equipment. The device becomes the main power source, which provides the required current supply.
• Electrodes or filler wire. The selected elements must correspond to the selected welding method.
• Gas cylinder with connecting hoses.
• Grounding for electrical equipment;
• Technical means of protection.

When welding aluminum, you should be guided by certain conditions:

• wire and electrode - at an angle of 90 degrees;
• the additive is supplied by reciprocating manipulations;
• Transverse vibrations of the tungsten electrode are unacceptable;
• maintaining an arc length from 1.5 to 2.5 mm;
• welding of thin aluminum is carried out with a lining of steel or copper to remove heat and avoid burn-through;
• The welding process occurs from right to left.

Safety precautions

Welding aluminum at home is quite unsafe. At home, the risk of traumatic situations occurring is at a high level. Gas and electrical safety instructions must be followed.

Welding aluminum parts involves protecting the worker himself. It is necessary to use full welder equipment (robe, mask) and some other auxiliary personal protective equipment.

Before you start connecting aluminum with your own hands, you should familiarize yourself with the video, which explains the basic rules for working with the holder and equipment.

Welding aluminum is not an easy task. This process requires some skill. If you follow all the rules and recommendations for welding finicky metals, you can achieve the desired result.

Source: https://respect-kovka.com/flyus-dlya-svarki-alyuminiya-svoimi-rukami/