How to weld metal correctly

Welding thin metal with an inverter

Many structures are made from thin steel. These are car bodies, containers for liquids, and small diameter pipes. At enterprises, welding of thin sheets of metal is carried out with special machines that ensure optimal connection. But how to weld such materials at home? What electrodes are suitable? What machine modes should you use to stitch? Welding thin metal with an inverter will be successful if you know the answers to these questions and also watch the corresponding video.

Features of working with sheet iron

Not all welders can weld steel sheets 1-1.5 mm thick. This requires certain knowledge and skills. But if you show persistence and practice, and also study a video on how to weld thin metal with an inverter, you can achieve significant success.

Welding thin metal is complicated by the following factors:

Burns. Since the material being welded is quite thin, through holes often occur in it. This is the most common mistake made by beginner welders. The reason is the incorrectly selected current strength and slow welding.
Lack of penetration. Wanting to avoid the first defect, welders are too hasty when passing the joint, and unwelded areas remain. This spoils the tightness of the connection and makes the product unsuitable for working with liquids. The resistance to breaking and breaking is also low. The correct settings of the inverter and the choice of electrodes help in solving the situation.
Sagging on the reverse side. Welding thin sheet metal is accompanied by another common problem - protruding beads on the back of the surface. From the front part, the product has an even seam, without pores or lack of fusion, but the molten metal of the weld pool, under the influence of gravity, pushes the seam section to the other side. The situation can be solved by using special substrates or reducing the current strength, and changing the suture technique.
Structural deformation. Sheet steel quickly overheats, which leads to expansion of the intermolecular component. The structure begins to stretch in the heating zone. Since the edges of the product remain cold, the surface becomes covered with waves or a general bend. On non-critical products, cold straightening of the mold with rubber hammers is possible. But if this is not possible, then a certain alternation of suture application along the entire length is used.

Electrodes used

To successfully cope with such work, it is important to choose the right electrodes for thin metal. Since welding is carried out at low currents, the use of electrodes with a diameter of 4 and 5 mm will “strangle” the electric arc, preventing it from burning normally.

The best option for connecting thin metals are electrodes with a diameter of 2-3 mm. Arc welding will be successful if the consumables are pre-heated at a temperature of 170 degrees. This will allow the coating to melt evenly without interfering with arc manipulation and weld formation.

Electrodes for welding thin metal must have a high-quality coating. The technology for working with sheet steel involves an intermittent arc, for which the electrode is briefly detached from the weld pool. If the coating is refractory, the result will be the formation of a kind of “visor” at the end of the electrode, which interferes with contact with the surface and resumption of the arc.

Machine modes and welding parameters

Experienced welders know how to weld thin metal by testing a variety of machine settings. As a result, optimal parameters were derived that are well suited for this type of work. Here are the main settings:

Metal thickness, mm	Current strength, A	Electrode diameter, mm
0.5	10	1
1	25-35	1.6
1.5	45-55	2
2	65	2
2.5	75	3

It is important to set the welding current lower than when working with thick plates. This will help avoid burns and leaks. Inverters that allow cooking with alternating voltage but at high frequencies, as well as direct current devices, have proven themselves to be excellent in this area.

If the unit settings allow you to set the starting voltage level, then you should take advantage of this and set a lower value (by about 20%) than the operating current. This will prevent the area from being scorched when starting to ignite the arc and will help to start welding immediately at the joint. If the starting current is not regulated, then you can ignite the electrode on a thick surface and then transfer it to the joint.

Welding thin metal involves working at low currents. To do this, the inverter settings must maintain the operating values of the ammeter at the level of 10-30 A. If the minimum adjustable value is higher than these parameters, then it is possible to reduce the current strength with additional resistance in the circuit. For this, a high-carbon steel spring is used, placed between the product and the ground cable. Installing an additional ballast that reduces the current to the required level will also help.

If the device settings support the pulse mode, then you can use this. Especially thin steel is welded with an intermittent arc. The pulsed current will automatically break the arc, allowing the metal to cool.

Welding technique

Welding thin-sheet iron requires proper approach of the edges of the plates to each other. Butt joints often result in burn-throughs and are only suitable for experienced welders. If possible, it is worth placing the plates overlapping. This will create some basis for the deposited metal, and will not allow burning through the entire product. In this case, the electrode is directed primarily to the bottom plate, since a different position will lead to undercuts on the top side.

When joining into a butt, the edges are not cut. There is no need for a gap either. It is necessary to bring the ends of the parts together as tightly as possible and tack. Low current strength and thin electrodes make the work much easier. You can then cook it in several ways:

Set the current to low and quickly sew the seam without oscillating movements, strictly along the connection line.
Raise the current a little higher, but conduct the seam with an intermittent arc, giving the metal time to cool before the next “portion” of the additive.
Cook using the methods described above, but using a special substrate to maintain a heated area and avoid sagging. A metal table will not work here, since the product may be partially welded to it. A good alternative would be a graphite backing.
To prevent severe deformation, apply stitches in a checkerboard pattern, or in small sections (100 mm each). With the latter method, it is necessary to finish the next seam at the beginning of the previous one. This will allow the product to be heated evenly along its entire length and minimize deformation.

Welding is carried out with a short arc, which allows you to quickly form a seam and avoid overheating of the area. Increasing the distance between the end of the electrode and the surface visually prevents burning of the plates, but does not contribute to the formation of a welding bead. The electrode is held towards itself at an angle of 45 degrees, or tilted to the side. Right angles should be avoided as this leads to burns.

Alternative Methods

In addition to inverters, a semi-automatic welding method is also well suited, especially when working with car bodies. The advantage is that there is no need to change the electrode, since the wire is fed continuously. This significantly speeds up the entire process for large projects. The distance between the product and the heating pad is easier to control since there is no combustible part of the electrode. This method is easier for beginner welders to master.

Semi-automatic welding allows you to work with even thinner sheets of steel due to the use of 0.8 mm wire. But such equipment is not always available in everyday life, so the inverter method remains in demand. After considering these tips, it becomes clear how to properly weld thin metal. Additional videos about working with an inverter and semi-automatic machine will help you consolidate your knowledge and start practicing.

Source: https://svarkalegko.com/tehonology/kak-varit-tonkij-metall.html

How to learn to weld metal - step-by-step instructions for beginners

During any construction work, it often becomes necessary to work with metal, in particular welding or cutting. And if there should be no problems with cutting metal, since you can use a grinder, then you will have to work hard with the connection, since you won’t get far without welding.

In cases where construction or repair work is carried out independently, you can also weld two or more metal structures yourself. In this article we will learn how to weld metal correctly.

Basics of electric welding

Connecting two different metal parts into a single whole is not a problem today. The use of an electric arc allows you to do this even when a beautiful and neat joint seam is required.

Welded pieces of metal are obtained in one piece, since a very high temperature arises at the joint, which causes the metal to melt at the joint and weld to each other. Therefore, welding metal by electric welding in modern realities is not something impossible.

Types of welding

In general, electric welding is usually divided into two types, where direct or alternating current works. For direct current, an inverter is used, and for alternating current, a transformer is used.

When using the latter, many problems and difficulties are caused, such as power outages, loud noise, bulkiness and heaviness of the device also do not cause pleasant sensations.

With an inverter, absolutely everything is exactly the opposite, so if you decide to learn how to weld even thin metal, then be sure to start with it. The weight of the device will not exceed eight kilograms, and the neighbors will not even know that you are cooking something unless they see it.

Welding technology

To weld metal, you will need two parts that allow current to pass through and also have opposite charges. In this case, they are a metal part and an electrode. When two parts that have different polarities come into contact, an electric arc is created, which is aimed at melting the metal. In this case, both the metal part itself and the electrode begin to melt.

In this case, the consumable electrode is directed into the weld pool along with the arc. The protective coating of the electrode also melts at high temperatures, so it has a protective effect so that oxygen does not enter the epicenter, and gases are also released during operation.

It is important to understand that the slag that melts from the electrode must also enter the weld pool in order to maintain the melting temperature.

In general, welding of metals is achieved only by the electrode and its melting, so it is important to move it at a certain speed over the place where two parts of metal need to be welded. This molten electrode ultimately creates the seam pattern.

When the molten mass begins to dry, a kind of shell is formed at the seam site, which protects the joint from the ingress of unnecessary gases. As it cools, beat it off with a hammer, but you need to be careful and protect your eyes, since flying fragments are often still burning and can get into your eyes or skin.

Precautions and preparations

All work should begin with preparatory activities at the production site. Caution is important, as there is a high risk of injury not only from melting material and extreme temperatures, but also from high voltage, because welding only works from the mains.

The thickness of the welded metal for beginners who are just learning how to weld metal should be larger, since it is much easier to do this with such material.

For the work you will need the welding device itself, leggings and, of course, a welding helmet. It is better to choose tight clothing to cover all exposed areas of the body; shoes should be made of thick leather to withstand sparks and fragments.

You will also need a metal brush and a hammer to beat and clean the slag. It is better to check the quality of the welded metals after work, so you will not only understand how strong the structure was welded, but also generally understand the result of the process.

Photo of the metal welding process

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Source: https://instrumentgid.ru/kak-nauchitsya-varit-metall/

How to weld metal for a beginner

Every household constantly needs to build or repair some kind of metal structure. The strongest connection between two metal parts is welding. Forge welding has been known to mankind for several millennia, while welding with an electric arc or gas torch has been known for a little over a century.

And if the craft (or even the art) of a blacksmith required many years of training and accumulation of experience, then electric arc welding at the initial level, if desired and with the appropriate equipment, can be mastered in a few days.

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Welding Basics

To learn how to weld correctly, you need to understand the physical foundations of the welding process. Any welding machine creates in a small working area at the junction of two parts being welded a temperature above the melting point of the metal being welded, the so-called weld pool.

In it, the part of the metal of both parts that has turned into liquid is mixed with each other and with the metal of the molten electrode. After the temperature decreases, the metal from the weld pool crystallizes, connecting the welded parts into one whole. By slowly moving the weld pool following the arc along the joint, the welder creates a seam.

High temperatures in amateur welding machines are achieved in two ways:

electric arc;
gas burner.

Electric welding is safer, since there is no risk of gas explosion, and is easier to learn for those who are just learning how to weld properly.

An electric arc is created by passing a high current through the air gap between the parts being welded and the electrode.

How to cook properly

To understand how to cook properly, a small amount of theory should be supplemented with a large amount of practice. It’s best to start learning by welding scraps of corners, fittings, and metal plates. Only after you “feel the seam” with your own hands can you begin to connect more or less important structures.

Arc Welding Process

There are several types of devices; in order to learn how to cook correctly, it is best to start with an inverter. It allows you to smoothly regulate and maintain a stable operating current, is slightly independent of the level and stability of the voltage in the supply network, and does not create voltage surges in this network.

Welding technology

Welding work takes place at high temperatures. The electric arc is a heat source for heating and partially melting the work area. It occurs in the air gap between the workpiece and the electrode, is maintained throughout the operation and moves smoothly along the seam line.

The dimensions of the resulting working zone of molten metal, or weld pool, are determined

selected operating mode;
speed of electrode movement;
weldable materials;
the thickness of the parts and the configuration of the edges.

Average dimensions of the weld pool:

width - 0.8-1.5 cm;
length 1-3 cm;
depth - about 0.5-0.7 cm.

To weld correctly, it is necessary to select the material and thickness of the electrode in accordance with the thickness of the parts being welded. The electrode is coated with a thin layer of flux, or coating.

When heated, this flux melts and forms a protective gas region above the working area, which prevents air oxygen from entering the working area.

As the electric arc is removed and the weld pool zone follows, the molten metal crystallizes, forming a seam that connects the parts into a single whole. On top of the seam there is a thin layer of burnt-out flux residue that needs to be cleaned off.

Types of Welding Machines

There are a large number of models of welding machines of different types on the market.

Of all their diversity:

transformers;
rectifiers;
inverters;
semi-automatic;
machine guns;
plasma;

In a home workshop, transformers are most often used because of their low cost, and inverters because of their simplicity and ease of use. The rest require either special working conditions, achievable only in production, or special training and long-term acquisition of skills.

Transformer

The design of such devices is extremely simple - it is a powerful step-down transformer, in the secondary winding of which a working electrical circuit is connected.

Transformer welding machine

very large weight and dimensions;
low arc stability;
AC operation;
causes voltage surges in the supply network.

Such a device requires skill and extensive experience from the welder. It is not suitable for teaching a novice welder how to weld correctly.

Inverters

The inverter device has a much more complex design. The inverter unit repeatedly converts the input mains voltage, bringing its parameters to the required ones. Due to the transformation of high frequency current, the dimensions and weight of the transformer are many times smaller.

low weight and dimensions;
stabilized voltage and current in the circuit;
additional anti-stick and hot start functions;
possibility of precise adjustment of current and arc parameters;
does not cause voltage surges in the supply network.

The inverter also has disadvantages:

high price;
low frost resistance.

It’s best to start learning how to cook properly with an inverter. The stability of the arc parameters and additional functions that make starting easier and preventing “sticking” will allow the beginner to concentrate on the seam and quickly master the technology.

What does a novice welder need to get started?

To start training, you will have to select the appropriate equipment and equipment.

Particular attention should be paid to personal protective equipment, since welding work is a process harmful to vision and respiratory organs.

It will be necessary to equip a workplace; if it is in a workshop, then the room should be equipped with effective exhaust hood and sufficient lighting.

If you decide to start training outdoors, be sure to do so on dry ground and under a canopy that will protect you and the equipment from rain.

The workplace should be spacious, not cluttered, and not restrict the welder’s movements.

Cables should be laid out in such a way that they will not be stepped on or tripped over when moving around workpieces.

It is better to choose scraps of rolled stock and steel sheets as blanks for practicing skills. It is not recommended to start with critical structures.

Tools and protective equipment

Uniforms and personal protective equipment include:

welder's mask with a built-in light filter to protect the eyes from bright light and ultraviolet radiation from the arc;
split-leaf gloves—gaiters to protect hands from splashes of hot metal;
thick clothing made of non-flammable fabric;
cap under the mask;
durable shoes.
a respirator to protect the respiratory system from generated gases and dust, especially when working with non-ferrous metals.

Tools, materials and equipment you will need:

Angle grinder (grinder) for cutting workpieces and cleaning seams;
A set of hand tools - hammers, chisels, pliers, etc.;
Metal brush for cleaning workpieces;
Clamps and clamps for connecting workpieces;
Electrodes.

And finally, the inverter with the included cables and holder.

Which electrodes to choose

In order to start learning to weld correctly, you need to select welding materials in accordance with the materials being welded and their thickness. It is better to choose ordinary low-carbon structural steels as a training task. Widely used coated electrodes are suitable for them.

Electrodes for welding machines

They usually study on electrodes with a diameter of 3 mm, 1.6 and 2 mm are used to work with thin-walled structures, and 4-6 mm are used for welding thick-walled workpieces.

Most often, electrodes with a diameter of 3 millimeters (three) are used at home. Thinner ones are suitable for welding thin-walled parts, and numbers four and five are for thick elements.

The power of the device must correspond to the diameter of the electrode (or its number). In the user manual (and on the device body) there is a table for determining the operating current depending on the number.

Recommendations on how to weld metal correctly

To weld metal correctly, it is not enough just to learn how to make seams. The welder must also be a materials scientist - know a lot about the properties of the materials being welded, their interaction with each other and with high temperatures.

The technology includes many operations before and after the actual seam is completed.

Before starting the main operation, the parts to be welded must be thoroughly cleaned of mechanical impurities, old paint, rust and must be degreased. It is also necessary to correctly position them relative to each other and fix them in this position.

When connecting thin-walled structures or simply long seams, the parts are clamped to each other at several equally spaced points to avoid thermal deformation.

The future welder must know and anticipate in advance:

potential problems;
types of defects

and think about how to avoid them.

Start with the three simplest types of connections

Butt. The edges of the parts to be joined are in the same plane with a small gap between them, and this gap is filled with suture material.
Overlapping. The parts are arranged with some edge overlap.
Tavrovy. One plate is welded end-to-end in the middle of the other, usually at a right angle.

Source: https://MyTooling.ru/instrumenty/kak-svarit-metall-novichku

How to weld metal with an electrode correctly

Almost every person has encountered a situation where it was necessary to weld some metal part. Most often this happens during construction work. It’s great if a man knows this process, but sometimes you have to turn to professionals in your field. But you can learn welding on your own. Beginners usually start by learning seams. Complex work should begin only when the home craftsman learns how to weld using electrodes correctly.

Basic Concepts

Welding today is the most reliable metal connection, because it fuses materials into one whole. The procedure takes place under the influence of high temperatures. Most welding machines use an electric arc to operate.

The principle of its operation is as follows : it heats the metal in a certain small zone to the melting point. This type of welding is called electric arc welding.

When forming an electric arc, both direct and alternating current can be used. For alternating voltage, transformers are used, for constant voltage, inverters are used.

The work is easier with inverters, since they operate on a 220 V network. They are small in size and weight, about 4-8 kg. They make almost no noise and do not affect the voltage.

It is much more difficult to work with transformers, since the current is alternating, it affects voltage surges, which neighbors and household appliances are usually not very happy about. The device is large and heavy.

Thus, it becomes obvious that a welding inverter is more suitable for beginners .

Required Tools

For welding work you need a set of tools and special protection. This is the welding machine itself, electrodes, hammer and brush. The diameter of the electrodes depends on the material to be worked on.

Don't forget about protection . To protect your eyes, a welding mask is a must, and you should also wear thick clothing, suede gloves, and durable shoes. Devices that convert alternating current into direct current are also useful - this is a rectifier, inverter or transformer.

Work technology

For an electric arc to occur, conductive elements are needed: in this case, it is metal and an electrode. When metal and electrode come into contact, an electric arc appears. In the same place, the metal immediately begins to melt, and at the same time the electrode melts and is transferred to the weld pool.

Also in the process, the protective surface of the electrode burns, partially evaporating and releasing a certain amount of gases. These gases create a curtain and protect the metal from oxidation. The metal is also coated with slag, which helps the metal by maintaining its temperature.

The formation of a seam occurs when the electrode moves, which is the whole secret of welding. also necessary to monitor the angle of inclination and current parameters . After the metal cools, a slag crust remains on it, which protects the metal from oxidation. The slag is then beaten off using a hammer.

How to learn to cook

At first, welding work must be carried out under the supervision of an experienced welder; he will show you how to learn how to weld, give advice and help in case of problems. You can practice on a piece of metal.

For beginner welders, a 3 mm electrode is most suitable . It costs a little more, but is easier to work with. Later, as experience is gained, you can move on to other options. You can fix it in a special holder, which can be spring or screw and is attached to one of the cables. After fixing the electrode, you can begin connecting the cables.

The welding machine has two outputs : positive and negative. There are also two cables, one of them ends with a holder into which the electrode is inserted, the other with a special clamp.

In conventional types of welding, straight polarity is connected: minus goes to the electrode, plus to the part. But in some work, reverse polarity is used.

Electric welding process

After preparing all the parts and devices, you can start working. First of all, attach the cable with the clamp. Then you need to check the other cable for insulation and reliable fixation of the electrode. Then the current power is set on the welding machine depending on the diameter of the selected electrode.

An electric arc is ignited. To do this, you need to lightly touch the metal with the electrode , and sparks should fly out. After the first contact, the electrode touches the metal and rises to a height of 5 mm.

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The height of 5 mm must be maintained throughout the entire operation. As the process progresses, the electrode should burn out and will need to be replaced . It can also periodically stick to the metal, in which case you need to shake it slightly.

After igniting the arc, you can proceed to fusing the bead. This is done with light oscillatory movements, smoothly moving the electrode. The result of the operation should be a seam with a slight deposit of metal.

Electrode movement can occur in three directions:

As you work, you can superimpose one option onto another. Each master prefers to work in his own direction. After all, the main task is to reliably connect metals, and how this happens is not so important.

Some nuances

It is not enough to simply move an electrode across metal. You need to know some of the nuances of welding and how to properly weld a certain metal. One of them is that the seam “pulls” the part, which can cause them to lead. And in the end the result will be completely different from what the master expected. Most often, this problem can be avoided by grabbing the part in several places, approximately every 10 cm. This is done on both sides, after which the main work begins.

How to choose the right current

In addition to bonding the metal before welding, you need to know what current value to set in certain situations. It all depends on the thickness of the metal being worked on and the diameter of the electrode.

But sometimes the voltage may suddenly drop, the inverter itself will not be able to react to this situation. In this case, you just need to slow down the movement of the electrode to warm it up. Repeatedly running the electrode along the seams may also help. If this does not help, you can install an electrode of a smaller diameter .

Pipeline welding

Using electric arc welding, you can make a horizontal seam that runs around the circumference of the pipe and a vertical seam that runs from the side, as well as top and bottom seams. The most convenient option is the bottom seam.

Steel pipes must be butt welded, welding all the edges along the height of the walls. During operation, the electrode must be installed at an angle of 45 degrees - this is done in order to reduce sagging inside the products. The seam width should be 2-3 mm, height - 6-8 mm. If welding is overlapped, then the required width is 6-8 mm, and the height is 3 mm.

Immediately before starting work, you need to carry out preparatory procedures :

The part needs to be cleaned.
If the edges of the pipe are deformed, then straighten them or cut them off with an angle grinder, or simply with a grinder.
The edges where the seam will go must be cleaned to a shine.

After preparation, you can start working. It is necessary to weld all joints continuously, completely welding . Pipe joints with a width of up to 6 mm are welded in 2 layers, with a width of 6-12 mm in 3 layers and with a wall width of more than 19 mm in 4 layers. The peculiarity lies in the constant cleaning of pipes from slag, i.e.

After each completed layer, it is necessary to clean it of slag and only then cook a new one. Particular care must be taken when working on the first seam, it is necessary to fuse all blunts and edges.

The first layer is carefully checked for the presence of cracks; if they are present, then they must be melted or cut out and welded again.

Source: https://crast.ru/instrumenty/kak-pravilno-varit-metall-jelektrodom

How to cook iron using electric welding? — Metals, equipment, instructions

How to cook properly

How to properly weld metal using electric welding - Women's secrets

In a private house, in a country house, in a garage and even in an apartment - everywhere there are many jobs that require metal welding. This need is especially acute during the construction process. Here, especially often, something needs to be cooked or cut off.

And if you can still cut it with a grinder, then there is nothing to reliably connect the metal parts with except welding. And if the construction is carried out with your own hands, then the welding work can be done independently. Especially in places where the beauty of the seam is not required.

We will tell you how to properly weld by welding in this article.

Basics of electric welding

Welded metal joints are the most reliable today: pieces or parts are fused into a single whole. This happens as a result of exposure to high temperatures.

Most modern welding machines use an electric arc to melt metal. It heats the metal in the affected area to the melting temperature, and this happens over a small area.

Since an electric arc is used, welding is called electric arc welding.

This is not a completely correct way of welding)) At a minimum, you need a mask

Types of electric welding

An electric arc can be formed by both direct and alternating current. Welding transformers use alternating current, and inverters use direct current.

Working with a transformer is more complicated: the current is alternating, so the welding arc “jumps”, the device itself is heavy and bulky. The noise that both the arc and the transformer itself makes during operation is also quite annoying.

There is one more problem: the transformer greatly “stresses” the network. Moreover, significant voltage surges are observed. The neighbors are not very happy about this fact, and your household appliances may suffer.

Inverters mainly operate from a 220 V network. At the same time, they are small in size and weight (about 3-8 kilograms), operate quietly, and have almost no effect on voltage.

The neighbors won't even know you started using the welding machine unless they see you. In addition, since the arc is caused by direct current, it does not jump and is easier to stir and control.

So if you decide to learn how to weld metal, start with a welding inverter. Read about choosing an inverter welding machine here.

How to learn to cook by welding

It all starts with preparing the workplace. Safety when working with electric welding must be given increased attention: there is a possibility of injury from both electricity and high temperatures. Therefore, take your preparation seriously.

It is more convenient to learn to weld with electric welding on a thick piece of metal: it is better to practice on it. In addition to it and the welding machine, you will need gaiters (thick gloves) and a welder’s mask.

You also need thick clothing that protects the entire body, and durable shoes with thick leather. They must withstand sparks and scale. You will also need a hammer and a wire brush to knock off the slag.

You will need glasses to protect your eyes.

How to connect the electrode

It will be easier for beginners to carry out welding work if they take a universal electrode with a diameter of 3 mm (3.2 mm, to be precise). They are more expensive, but easier to work with. After you learn how to weld metal, you can try using cheaper ones, but it’s better to start with these.

The electrode is inserted into a holder attached to one of the welding cables. There are two types of clamps - spring and screw.

If the electrode holder is spring-loaded, press the button on the handle and insert the electrode into the socket that appears. When screw clamped, the handle rotates. Unscrew it, insert the electrode and clamp it.

In any case, it should not wobble. After installing the electrode, you can connect the cables.

There are two outputs on a DC welder: positive and negative. There are also two welding cables:

one ends with a metal clamp-retainer - it is connected to the part;
the other is a holder for the electrode.

Which polarity to connect for welding depends on the type of work. If we talk about inverters, then more often the plus is connected to the part, and the minus is supplied to the electrode. This connection option is called direct polarity. But there is a list of works in which reverse polarity is applied: minus to the part, plus to the electrode (for example, for welding stainless steel).

Direct and reverse polarity of connection on the welding inverter

Straight polarity provides better heating of the metal, which is necessary for most connections. This is explained by the fact that electrons move from the negatively charged pole - with straight polarity, this is the electrode - to the positive - part. At the same time, they additionally transfer their energy to the metal, increasing its temperature.

We figured out how to connect the electrode to the inverter. Now about how to light an arc. It occurs when there is direct contact between the electrode and the part. There are two ways:

Everything is clear from the name: in one case, you need to run the electrode along the seam (so that there are no marks left), in the second, you need to hit the part with the tip of the electrode several times.

When the electrode is new, its tip is exposed, ignition occurs easily. If it was already in use, a wall of several millimeters of protective coating would form around the rod. This coating needs to be knocked off by hitting the part with the tip several times.

Both methods of ignition are used, here everyone chooses what is convenient for them. This skill is the first one you will have to master if you want to learn how to use electric welding.

Therefore, you take several electrodes, a thick piece of metal, and try to strike an arc. Once you have succeeded, you can proceed to the next stage of training.

Electrode tilt

The main position of the electrode is tilted slightly towards you - at an angle from 30° to 60° (see figure). The amount of inclination is selected depending on the required weld and the set current. Focus on the condition of the weld pool.

The first position is called the “backward angle.” In this case, the bath and molten slag moves behind the tip of the electrode. Its angle of inclination and speed of movement must be such that the slag has time to cover the molten metal. In this position, we obtain heating of the metal to a greater depth.

Manual arc welding technique: positioning the electrode at an angle forward and at an angle backward

There are situations when the metal does not need to be heated very much. Then the angle of inclination changes to the opposite, the seam and the bathtub “stretch” behind the electrode. In this case, the heating depth is minimal.

Electrode movements

The answer to the question “how to properly weld with electric welding” is simple: you need to control the weld pool. To do this, it is necessary to hold the electrode at a distance of 2-3 mm from the metal surface and control the condition and size of the weld pool. This is where the skill of a welder lies.

The difficulty lies in the fact that several parameters have to be controlled simultaneously:

move the electrode along one of the trajectories shown in the photo,
as it burns, lower it a little lower, maintaining a constant distance of 2-3 mm;
monitor the size and condition of the weld pool, accelerating or slowing down the movement of the electrode;
follow the direction of the seam.

The movements of the electrode tip are shown in the figure. Those who want to learn electric welding for home use do not need to master all of them, but you will need two or three movements: for different situations, seams and metals.

Another element of manual arc welding technique: the tip of the electrode must move along one of these trajectories (or something similar)

How to learn to cook with electric welding? Practice movements on a thick piece of metal. Then you get not seams, but rollers. This stage is the initial one. On it you will master the basic skills of a welder: learn to control the distance from the tip of the electrode to the part, and at the same time, move it along a given path, monitor the weld pool and the slag in it.

To do this, take thick metal and draw a line on it with chalk: you will need to lay a roller along it. You light the arc and begin to master the movements, learning to control the bath at the same time.

You won’t succeed the first time, or even the tenth time. You will probably use a dozen electrodes.

When the manual arc welding technique has been mastered: the bead is uniform, its width and height are constant (or almost), you can try to connect the parts.

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You should get similar rollers. This way you can learn how to weld using electrodes correctly.

Read how to make a gazebo on a metal frame in this article, and here the construction of a shed on a metal frame is described.

Learning to hold the electrode correctly and move the bath is not enough for a good result. It is necessary to know some of the subtleties of the behavior of the metals being joined. The peculiarity is that the seam “pulls” the parts, which can cause them to warp. As a result, the shape of the product may differ greatly from what was intended.

Electric welding technology: before starting to apply a seam, the parts are connected using tack welds - short seams located at a distance of 80-250 mm from each other

Therefore, before work, parts are secured with clamps, ties and other devices. In addition, tacks are made - short transverse seams laid every few tens of centimeters. They hold the parts together, giving the product its shape. When welding joints, they are applied on both sides: this way the resulting stresses are compensated. Only after these preparatory measures do welding begin.

Read about the types of welds and joints (horizontal, vertical, ceiling) and how to weld them correctly here.

How to choose a current for welding

It is impossible to learn how to weld using electric welding if you do not know what current to set. It depends on the thickness of the parts being welded and the electrodes used. Their dependence is presented in the table.

But with manual arc welding, everything is interconnected. For example, the voltage in the network has dropped. The inverter simply cannot produce the required current.

But even under these conditions you can work: you can move the electrode more slowly, achieving good heating. If this does not help, change the type of movement of the electrode - passing over one place several times.

Another way is to use a thinner electrode. By combining all these methods you can achieve a good weld even in such conditions.

Now you know how to weld properly. All that remains is to practice the skills. Choose a welding machine, buy electrodes and a welding helmet and start practicing.

To reinforce the information, watch the video lesson on welding.

Source: https://sekretzh.ru/kak-pravilno-svarivat-metall-elektrosvarkoj.html

Rules for working with electric welding for beginners

Owners of private houses, owners of dachas and garages perform many types of work independently, without inviting help. The exception is metal welding, which is traditionally considered a very difficult task.

However, for those who are seriously interested in the question of how to learn how to weld metal, it is quite possible to master electric welding.

After a little training, you can create simple structures from metal with your own hands, repair gates, pipelines, containers, make fences, gazebos, and barbecues.

Transformer or inverter

The best way to join metal materials is fusion at high temperatures. Metals in a liquid aggregate state form a single whole. No mechanical joint can provide such strength. You can create a temperature in a strictly defined zone at which the metal will melt using an electric arc.

It is no coincidence that the arc is called electric. It is formed under the influence of current and consists of a flow of electrons that release energy to the metal along the path of movement. This is how electric welding happens.

If alternating current is used, then electric welding is done using a transformer. The cost of the transformer is small compared to more modern equipment, but it is difficult to weld with it. It is noisy, produces an unstable temperature in the work area, and consumes a large amount of electricity. In addition, the neighbors will immediately become aware of the welding and will not hesitate to voice their dissatisfaction. A transformer can cause voltage surges in the network and overload it.

It is much more convenient to use inverter welding. The inverter is much more economical. You won't have to pay huge bills. The unit is small in size, produces a good quality arc, and can operate from autonomous energy sources. For beginner welders, an inverter is an ideal device.

Welding processes

An electric arc is formed by an electrode and a metal surface being processed. Taking into account the advice of the masters, you first need to take metal electrodes for electric welding. Graphite and carbon are intended for special work that home craftsmen rarely have to perform.

During electric welding, several processes occur in parallel, which it is advisable for beginners to know:

The main thing is the connection of liquid, brought almost to a boil, metal parts. As a result, a weld seam is formed;
by moving the electrode correctly, a good seam is formed;
Not only the metal melts, but also the electrode material. The melts flow into the working area, which is called the weld pool;
the protective layer of the electrode surface burns out. The combustion products of the protective layer of the electrode are released in the form of gases;
the resulting gases envelop the working area, block the access of air oxygen, preventing oxidation of the metal part;
A molten mass of slag is formed from the oxidation products. Often slag covers the entire working area (weld pool). As a result, visibility of the melting site deteriorates.

With proper electric welding, a flow of gases blows slag from the weld point onto the seam. At the end of fusion, the solidified slag is carefully knocked down with a hammer.

In order to weld metal correctly, you need to learn how to select appropriate current values, the angle of inclination of the electrode and practice the technique of moving it in the work area.

Working with electrodes

Having an idea of the essence of the electric welding process, you can begin working with the welding machine. You need to take all safety measures very seriously. The workplace should be cleared of unnecessary items and debris.

You will have to work with high temperatures and electrical equipment. Be sure to wear special protective gloves, a mask, thick clothing and shoes. The surfaces of the metal to be welded must be cleaned.

For electric welding you will need an electrode. There is no need to save money on purchasing your first copy. For novice welders, it is advisable to take a universal electrode with a diameter of 3.2 mm. It must be inserted into the welding cable clamp. How to insert is easy to figure out.

The electrode must be screwed into the screw clamp, and inserted into the spring holder into the niche that appears after pressing the key.

Check that the cables are connected correctly. In order to weld iron (this is the best option for starters), a cable from the inverter output with a “+” sign is connected to the part. The cable from the output with the “‒” sign is connected to the electrode. This connection is called direct. Cable connections are made in the reverse way when welding different alloys, for example, stainless steel. You will need this in the future.

Arc ignition

Then you need to turn on the inverter. This simplest procedure for electric welding is performed by turning on the toggle switch. The current value should be set using a regulator, which can be easily seen on the front panel of the unit. For the selected electrode, a current strength of 100 A is suitable. Lower the mask and proceed.

First of all, you need to practice arc ignition. With a new electrode, this is done by simply swiping it sharply across the part. Think about how you light matches. If the electrode has already been used, then you need to tap it on the surface of the metal. It happens that the electrode in the hands of beginners sticks to the metal. This can be easily corrected by sharply tilting the electrode to the side. If you can’t tear it off, you need to turn off the inverter. Then the sticking points will disappear on their own.

The ignited electrode forms a welding arc. To maintain it, you need to learn to maintain a distance of 3-5 mm from the metal. When approaching, a short circuit may occur, accompanied by sticking. As you move away, the arc will disappear.

Welding

After obtaining a stable arc, the welding process begins. To do this, move the electrode by slightly shaking it from side to side. Following this movement, the weld pool (working area) crawls. This is how the weld seam is formed. In the future, other seam trajectories can be mastered.

Sometimes, during the enthusiastic work of a beginner, the electrode is removed to an unacceptable distance and the arc disappears. It's easy to relight it. It is necessary to bring the electrode closer to the working area. The arc will be restored.

It should be remembered that when welding, the electrode is consumed and shortened. In accordance with this, you will have to lower your hand lower. When the length of the electrode decreases to 5-6 cm, you need to turn off the inverter and replace the used one with a new one.

At the end of welding, the resulting seam, after complete hardening, is cleaned with a hammer from slag deposits. What is left is a shiny, clean surface of the welded metal.

If you managed to get a relatively beautiful seam and firmly connect the metal using electric welding, then the first stage has been successfully completed. Very quickly the desire to develop skills further appears.

When electric welding, sometimes the seam pulls parts together, changing the shape of the entire structure. You need to learn how to use fixing devices: ties, clamps. Over time, you can master the technique of making transverse seams - tacks. They will first fasten the parts together, give them the required shape, which can then be secured with a full weld.

All skills are developed gradually. Knowledge, supported by the desire to master the craft, will lead to success.

Source: https://svaring.com/welding/teorija/pravila-elektrosvarki-metalla

How to weld metal correctly: basics, technology, recommendations - Website about

In cases where construction or repair work is carried out independently, you can also weld two or more metal structures yourself. In this article we will learn how to weld metal correctly.

How to weld thin metal with an electrode. Working as an inverter

The invention of the welding machine greatly simplified the process of joining metal objects. When working with thin workpieces, beginners may experience certain difficulties.

Welding thin metal with an electrode must be performed using welding machines that
allow this operation to be carried out without deformation or burning of the thin sheet.

Working as an inverter

Welding thin metal with an inverter allows you to perform this operation using reverse polarity. In this case, "-" is connected to the metal being welded, and "+" is connected to the electrode holder.

This electrode welding technique allows us to minimize the likelihood of deformation and burnout of the metal product. With reverse polarity, the electrode heats up significantly more than the metal being connected, so it is possible to complete the connection work as efficiently as possible.

To obtain a high-quality seam, it is necessary to use thin electrodes with a diameter of no more than 2 mm. Products that have a high melting coefficient should be used. This quality makes it possible to weld thin structures at low current, which will have a positive effect on the quality of the weld.

Welding thin sheets with an inverter should be carried out with a smooth movement of the electrode. In order not to burn the product and to ensure an even seam, it is necessary to position the electrode within 45 - 90 degrees to the surface to be welded. It is better to make the connection at an angle forward.

The level of connection depends on the quality of the electrodes used. Electrodes for welding thin metal with an inverter must be of good quality and, preferably, imported.

simple techniques for overlap and butt are shown.

Advantages of welding thin workpieces with an inverter

This method allows you to make a high-quality connection of thin metal. If welding work is carried out by a professional, then temperature deformation does not occur and the product will have an aesthetic appearance. With direct current, thin products can be cooked with less current, so the likelihood of burnout is significantly reduced.

The microprocessor control of such a device allows you to eliminate “holes” and voltage failures, generating an ideal output current that is suitable for welding work.

The only disadvantage of using an inverter is unstable operation at low air temperatures. Even high-quality devices fail at sub-zero temperatures.

Features of welding thin galvanized steel

If you need to weld galvanized steel, you will need to completely remove the zinc layer from the edges of the metal being joined. The zinc layer can be removed using a grinding machine or manually.

You can burn off the edges of the metal by welding, but you must be careful when doing this. Zinc vapor is very toxic and, if inhaled, can cause severe poisoning of the body. Work must be carried out only with a properly organized hood, or the product must be cooked outside.

Conclusion

We figured out how to weld thin metal with an inverter. The main thing is to properly prepare the workpieces, remove excess temperature, select electrodes, set the current and you can start working.

During the connection, it is necessary to carefully monitor the quality of the seam, tear off the electrode for a moment to prevent burn-through, and use heat-removing plates or wire. Only practice will help you master the process.

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Source: https://plavitmetall.ru/svarka/svarka-tonkogo-metalla-elektrodom-invertorom.html