How to insert an electrode correctly - Metals and their processing

Electric welding with electrodes for beginners: how to weld correctly - Machine

In a private house, country house or garage, quite often there is a need to connect various metal parts and create structures from them. It makes no sense to turn to professionals for help every time in such a situation, because you can purchase an automatic welding machine yourself.

A wide selection of different devices are available in stores in different price categories, so welding with an inverter for beginners is the best that the market has to offer.

Basics of electric welding

Inverter devices are characterized by fairly high efficiency and ease of operation. The main load for the operation of such equipment falls on the electrical network.

It has storage capacitors that allow you to accumulate electricity and ensure an uninterrupted welding process and soft ignition of the arc.

Unlike old devices, which provide a maximum boost of electricity for work, which can result in traffic jams, an inverter allows you to safely operate from a household power supply.

To understand how to cook using inverter welding, you need to understand the basics of its operation.

In such manual welding machines, the arc is formed as a result of contact of the electrode with the product. Under the influence of temperature, the metal and electrode melt. The molten part of the rod and the product form a bath.

The coating of the rod also partially melts, turning into a gaseous state and closing the weld pool from oxygen. This allows you to protect the product from oxidation.

Each electrode, depending on its diameter, is designed for a certain current strength. If you reduce it below the required value, then the seam will not work. Increasing this parameter will allow you to form a seam, but the rod will burn out too quickly.

At the end of the welding work, the coating cools down, turning into slag. It covers the connection of metal parts from the outside. By tapping the seam with a hammer, it is quite easy to get rid of the slag.

This is not easy to do because the electrode melts, so it must be fed into the welding zone at a constant speed. In addition, you must try to guide the electrode evenly along the joint in order to obtain a seam of maximum quality.

Welding methods

Nowadays there are many methods used for welding. They are divided according to various criteria. This information will be useful for a beginner, so you should definitely read it.

Depending on the heating, the edges of the product may completely melt or be in a plastic state. The first method also requires applying certain forces to the parts being joined - pressure welding.

In the second, the connection is formed as a result of the formation of a weld pool in which there is molten metal and an electrode.

There are other welding methods in which the product does not heat up at all - cold welding, or is not brought to a plastic state - connection using ultrasound.

Methods and types of welding.

Other types of welding are listed below:

Forge.
In this method, the ends of the joined products are heated in a forge and then forged. This method is one of the most ancient and is currently practically not used.
Gas press.
The edges of the products are heated with oxygen acetylene over the entire plane and brought to a plastic state, after which they are subjected to compression. This method is highly efficient and productive. Used in the construction of gas pipelines, railways, and mechanical engineering.
Contact.
The parts are included in the electrical circuit of the welding equipment and current is passed through them. A short circuit occurs at the point of contact of the parts, as a result of which a large amount of heat is released at the junction. It is enough to melt and join metal.
Butt, point and suture are varieties of the contact method of fastening the product.
Roller.
Used in joining sheet structures that require high-quality and reliable seams.
Termite.
The metal is held together by burning thermite, a mixture of iron oxide powder and pure aluminum.
Nuclear-water.
The edges of the product are melted by the action of an arc burning between two tungsten electrodes. The electrodes are connected to special holders through which hydrogen is supplied. As a result, the arc and liquid metal of the weld pool are protected by hydrogen from the harmful effects of atmospheric gases such as oxygen and nitrogen.
Gas.
The essence of the method is to use a flame to heat and melt parts. A flame is produced by burning a flammable gas in an oxygen atmosphere. The gas-oxygen mixture is produced using special burners.

The gas welding method refers to fusion welding. The gaps between the products are filled using filler wire. This method is widely used in various areas of human life. Most often found when joining thin-walled products, non-ferrous metals, cast iron.

When working with an inverter device, the polarity of the electrodes is of no small importance. Depending on the scheme, the heating intensity of the part changes, which allows you to create different welding conditions.

Step-by-step instructions for welding with an inverter

First of all, for welding you need to have protective elements:

gloves made of rough fabric;
welding mask with a special filter protecting the eyes;
a rough jacket and trousers made of material that will not catch fire from sparks that appear during welding;
closed shoes with thick soles.

Electrode position during welding.

Before you start welding with a welding inverter, you must take the necessary measures aimed at creating safe working conditions.

Proper preparation of the workplace consists of:

ensuring the necessary free space on the table, you should remove all unnecessary objects that could get splashed;
creating high-quality lighting;
Welding work must be performed while standing on a wooden floor that protects against electric shock.

Then the current is adjusted depending on the thickness of the parts and the electrodes are selected. The latter need to be prepared. If they were just purchased in a retail chain and their quality is beyond doubt, then this step can be skipped.

After preparing the electrodes, the ground terminal is connected to the product.

To obtain a high-quality and reliable connection, the metal must be prepared:

rust is completely removed from the edges of the product;
using solvents, various contaminants are cleaned;
At the last stage, the edges are checked for cleanliness; the presence of grease, paint and other contaminants is unacceptable.

Next you need to connect the welding inverter. It is better to carry out training on a thick metal sheet, forming a seam in the form of a roller. Make the first connection on metal lying horizontally on the table. Draw a straight line on it with chalk along which the seam will go.

Electrical circuit of the inverter.

In the process of training on such an object, you can significantly improve your welding technique.
The welding process begins with ignition of the arc.
There are two ways to perform this action:

scratching on metal;
tapping on metal.

The choice of method depends on the person’s preferences; the main thing when igniting is not to leave traces of welding outside the joint area.

After igniting the arc from contact with the metal, the arc is ignited, the welder removes the electrode from the surface of the part a short distance corresponding to the length of the arc and begins welding.

As a result, a weld is formed at the junction of two metal parts. It will be covered with scale - scale on the surface. It needs to be removed. This is very easy to do by tapping the seam with a small hammer.

Forward and reverse polarity

Melting of the metal for welding occurs under the influence of an arc. It, as noted above, is formed between the surface of the product and the electrode, since they are connected to opposite terminals of the device.

There are two main options for welding, differing from each other in the order of connection and called direct and reverse polarity.

In the first case, the rod is connected to the minus, and the part to the plus. In this case, an increased flow of heat occurs into the metal. As a result, a deep and narrow melting zone is formed.

Direct and reverse polarity.

With reverse polarity, the electrode is connected to the positive, and the product to the negative. In this case, the melting zone is wide and shallow.

The choice of polarity is entirely determined by the product you are working with. Welding can be performed with two types of polarity. When choosing, you should take into account the fact that the element connected to the positive is subject to greater heating.

For example, it is difficult to weld thin metal products due to possible overheating and burning. In this case, the part is connected to the minus. Currents are also selected according to the diameter of the electrode and the thickness of the metal. This data is taken from a special table.

Effect of electrode feed speed

The feed rate of the welding electrodes must provide the required amount of molten material supplied. Not having enough of it can lead to undercutting. This factor is very important in both direct and reverse polarity when welding.

During electric arc welding, due to the rapid movement of the rod along the joint, the arc power may not be enough to heat the metal. The result is a shallow seam that lies on top of the metal. The edges remain unmelted.

Slow advance of the electrode leads to overheating. In this case, it is possible to burn the surface and deform the thin metal.

Modern welding machines have a wide range of different functions and capabilities. Nevertheless, at the moment, most of the quality work done is still determined by human skill.

Effect of current

Welding current selection table.

When mastering the basics of welding with an inverter, it is important to understand what current strength needs to be set in each individual situation. A properly configured inverter welding machine is the key to success.

Data on the current value are taken from the table, which also shows the size of the electrodes. However, these current values are not exact; they are plus or minus several tens of amperes.

Features of welding thin metal

In everyday tasks, we are most often faced with the need to join thin metal. In this case, it is necessary to remember the basics of inverter welding for beginners, namely the importance of connecting the product to the correct pole. Thin parts are connected to the “minus” of the welding machine.

Here are some useful tips that can help improve your skills:

start cooking using the minimum current;
form the seam at an angle forward;
use reverse polarity;
secure the part to reduce distortion during welding.

Common mistakes made by newbies

Beginner welders tend to make mistakes due to ignorance of the basics regarding the use of welding equipment. For example, beginners may not know how to choose the correct polarity for welding with an inverter, which will lead to poor-quality joint formation or even burning of the part.

The following main errors can be identified:

neglect of safety precautions;
incorrect choice of welding machine;
use of low-quality or unprepared electrodes;
work without trial seams.

Let's sum it up

Having learned to work with welding equipment, it will be possible to solve many everyday problems that often arise when working in the country or in the garage. Beginners should pay special attention to the polarity of welding parts of different thicknesses with an inverter.

By understanding how to properly configure the equipment and choose an electrode, you will be able to obtain high-quality seams on any product. Be sure to pay attention to the forward and reverse polarity of connecting the welding inverter.

When welding thick parts, direct polarity is used when welding with an inverter, and for thin parts, reverse polarity is used.

Source: https://regionvtormet.ru/instrumenty/elektrosvarka-elektrodami-dlya-nachinayushhih-kak-pravilno-varit.html

How to properly hold the electrode when welding with an inverter

You bought a welding machine and want to learn how to weld with an inverter for beginners.

There is no need to be afraid of difficulties! The inverter machine is easy to use; anyone without experience or knowledge can master the welding process in a short time.

Equipment, equipment, safety precautions

Safety precautions. Welding production is associated with electrical voltage, or in common parlance - current. The current is invisible, but can kill a person.

We check the welding cables for serviceability and connect them to the inverter equipment. Return cable with a clothespin on metal to the negative connector. Cable with electrode holder to connector +. We insert the electrode into the electrode holder.

When connecting the device to the network, visually evaluate the current-carrying cables for serviceability. After making sure that the cables are in good condition, we plug in the plug into the socket and the toggle switch on the device, having previously set the current regulator to the lowest value. If the cooling fan starts working smoothly, without crackling or noise, then everything is fine.

Metal weight. When connecting heavy structures, take precautions. If multi-ton products collapse, they can lead to death or disability.

Equipment. Welding production involves high temperatures. The welder must have:

canvas mittens (gaiters);
robe (special suit);
mask with a light filter;
respirator for work in confined spaces;
boots with rubber soles.

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Gaiters are used when welding at heights, when arms are raised up, and mittens in other cases.

welding machine;
hammer;
brush;
electrodes.

Electrodes are selected according to the metal (carbon content, additives) and diameter, depending on the thickness of the metal and the technical characteristics of the inverter.

Inverter Welding Basics

For beginners, experienced welders advise attaching the holder cable to the body, pressing it with the elbow of the arm and wrapping it along the forearm (from the elbow to the hand), and taking the holder in your hand. This way the shoulder joint will pull the cable, and the arm and hand will remain free.

The method will help you manipulate your hand with ease.

Correct placement of the cable on the forearm. You should not work with bare hands.

If you simply take the holder in your hand without wrapping the cable around your forearm, then during the welding process your hand will get tired and wrist movements will cause the cable to dangle. Which will affect the quality of the welded joint.

How to cook using inverter welding correctly? We set the welding current on the machine according to the diameter of the electrode, the type of connection and the welding position. Setup instructions are available on the device and the electrode pack. We take a stable stance, move our elbow away from the body (no pressing), put on a mask and begin the process.

For beginners, it is better to start welding with an inverter with metal workpieces larger than 20 cm.

It is known that a beginner, putting on a mask and lighting an arc, stops breathing, trying to boil the entire length of the workpiece in one breath. With short products, you will develop the habit of cooking in one go. Therefore, practice on long workpieces, learning to breathe properly when welding.

Workpieces (plates) on the work table can be placed in a horizontal plane - vertically towards you or horizontally, it makes no difference.

At the beginning of welding, place the electrode clamped in the holder at an angle of 90 degrees (perpendicular) and move it towards the seam by 30-45 degrees. Light the arc and start moving.

If welding is performed at an angle backwards, then the tilt of 30-45 degrees goes towards the seam.
If the connection occurs at an angle forward, then the electrode is tilted away from the seam.

The distance between the surface to be welded and the electrode is 2-3 mm, imagine that you are running a pencil along a sheet of paper.

Please note that when welding, the electrode decreases as it burns - gradually bring the melting rod closer to the surface at a distance of 2-3 mm and maintain an inclination angle of 30-45 degrees.

Watch a useful video on how to learn how to weld with electric welding for beginners:

How can a beginner learn to weld with a welding inverter?

First we learn to light and hold an arc. Feel the edge when to bring the electrode closer to the surface to be welded during combustion so that the arc does not interrupt.

The electrode is ignited in two ways:

The new electrode ignites easily. A slag film appears on the working rod, preventing ignition. You just need to tap longer to break the film.

To facilitate arc ignition, inverter devices have a built-in Hot Start function.
If a beginner quickly brings the electrode closer to the surface, the Arc Force function (arc force, anti-sticking) is activated, increasing the welding current, preventing the electrode from sticking.
If the melting rod gets stuck, the Anti Stick function cuts off the current, preventing the inverter from overheating.

What is arc force on a welding inverter and how to use it.

It is better for a beginner to first learn on a thread seam; the electrode is held smoothly, without oscillatory movements.

After mastering thread technology, proceed to welding metal with oscillatory movements. Which are used on thick metal for heating, holding the electrode at a certain point using movements - herringbone, zigzags, spiral or your own method.

Types of oscillatory movements

At the beginning of the connection, we carry out several movements from left to right, forming a weld pool and go along the seam making oscillatory movements. The angle of inclination of the electrode is 30-45 degrees. After passing, we beat off the slag with a hammer and clean it with a brush. Take care of your eyes, wear glasses.

Tip: at the end of the weld, make oscillatory movements to the sides and move the electrode towards the deposited metal. This trick will add beauty to the welded joint (get rid of the crater).

how to weld corner joints, butt joints and overlap joints.

single-pass (one pass replenishes the thickness of the metal);
multi-pass.

A single-pass weld is performed on metals up to 3 mm. Multi-pass seams are applied for large metal thicknesses.

Welders check the quality of the seam with a hammer - they strike next to the seam. If the seam is smooth, without irregularities, then after the impact the slag flies off completely, there is nothing for it to catch on. It is important to select the correct temperature regime: an overheated seam (hot) will break, an underheated one - there is a risk of lack of penetration.

The current is selected based on the diameter of the electrode, in theory 30 A per 1 mm of electrode diameter.

Direct and reverse polarity when welding with an inverter

Let's consider polarity when welding with an inverter. With a DC connection, the movement of electrons is constant, which reduces spattering of molten metal. The seam is of high quality and neat.

The device has a choice of polarity. What is polarity is the direction of movement of electrons depending on the connection of cables to equipment connectors.

Reverse polarity when welding with an inverter - minus on the workpiece, plus on the electrode. The current flows from minus to plus (from the workpiece to the electrode). The electrode heats up more. Used for welding thin metals, the risk of burn-through is reduced.
Straight polarity - minus on the electrode, plus on the workpiece. Current moves from the electrode to the workpiece. The metal heats up more than the electrode. Used for welding thick metals from 3 mm and cutting with an inverter.

The polarity is indicated on the pack of electrodes; these instructions will help you correctly connect the wires to the equipment.

Welding thin metal with an inverter

The essence of connecting thin plates comes down to selecting small-diameter electrodes and adjusting the welding current. For example, for metal with a thickness of 0.8 mm, electrodes with a diameter of 1.8 mm are used. The current on the inverter is set to 35 A.

Technology occurs in intermittent movements. Watch a video showing how to join thin plates in detail.

How to cut metal with a welding inverter

To properly burn a hole in a pipe, we set the current on the device to 140 A for a 2.5 mm electrode. We light the electrode, placing it in one place to warm up the metal and press it in. We move the electrode to a new place, warm it up and press it in. Gradually, we cut a hole in the pipe.

When cutting, it is better to place the plate vertically so that the molten snot flows down. If you cut in a horizontal position, icicles will harden at the bottom of the cut. That's all the tricks!

Beginners are tormented by the question, which polarity of wires is better when cutting with an inverter?

When cutting with electric welding, straight polarity is preferable. The melting zone is narrow but deep.
With reverse polarity, the melting zone is wide but shallow.

Source: https://crast.ru/instrumenty/kak-pravilno-derzhat-jelektrod-pri-svarke

How to properly hold the electrode when welding?

Before deciding how to properly hold the electrode when welding, you need to take into account the thermal conductivity and chemical composition of the metal, current and voltage parameters, movement of the electrode end, arc length - they directly affect the quality of the connection. Low-carbon iron alloys are best welded; steels with a high carbon content and cast iron require preheating.

Types of electrode position during welding

A serious aspect of welding technology for performing high-quality metal welding is the correct choice of the position of the electric current conductor. The angle of inclination of the electrode during welding directly depends on the positions. There are three main options for location relative to the surface plane:

angle forward;
at right angles;
angle back.

Electrode position when welding

When positioned at an angle forward, the tilt value will be in the range of 30–60 degrees. In this case, the liquid slag moves in the direction of the weld pool and manages to cover the molten area of the metal. That small part of the liquid slag that falls will be displaced by heavier molten metal.

If the amount of slag in front increases, the inclination angle should be reduced. When it is clear that the liquid slag completely floods the bath and does not have time to harden, you should take the position of the electrode “At a right angle”. Then gradually decrease the angle value. You need to maintain a balance.

For shallow penetration of the base metal, you need to choose this particular position of the electrode when manual arc welding.

At right angles. The working angle in this position is 90 degrees. This is the most correct position of the electrode when welding in hard-to-reach places where there is no possibility of choosing any other angle of inclination. This approach is also necessary to obtain penetration of the base metal to an average depth.

Angle back. This approach provides a range of tilt angles from 30 to 60 degrees back. The use of this position strongly pushes the liquid slag back and holds it behind the fused weld pool. It is necessary to choose the correct angle value so that the liquid slag has time to follow the electrode and cover the molten metal. This position of the electrode during welding is used for deep penetration of the base metal.

Main types of movement of the electrode end

One of the most important criteria is the degree of required effort (volume of deposited metal) for high-quality welding. Welding seams can be divided into:

normal (seam with a flat surface);
reinforced (convex seam);
weakened (concave seam).

To perform a particular weld, in addition to obtaining the required volume of deposited metal, it is important to use the method of melting the edges that will be weldable. This can be achieved by knowing how to properly hold the electrode when welding with an inverter, namely: maintaining a constant distance between the electrode and the workpiece and choosing the necessary technique for moving the end of the welding conductor of the electric current.

Types of simultaneous electrode movements:

progressive;
straight;
oscillatory.

Schematic representation of electrode movement

The movement performed along the electrode axis, guaranteeing a constant arc size and speed of the welding process, is called translational.

During manual arc welding, the movement of the electrode along the axis of the seam, which makes it possible to control the speed of the melting process and the quality of seam formation, is called linear.

An oscillatory movement performed across the suture axis with an inclination of 45 degrees is applicable for heating the edges and controlling the width of the seam. Some types of electrodes for manual arc welding of thin-sheet rolled products or for performing root welds cannot withstand this movement plan.

Distance between electrode and workpiece

The question at what distance to hold the electrode when welding is important, since this directly affects the quality of the seam created, its shape, size, as well as its roughness. The distance or magnitude of the arc does not actually affect the depth of penetration of the base metal. When electrode welding, the arc length can be:

very short;
short;
medium and long.

The most optimal arc size is 2-3 mm.

Welding arc length

When working with an electrode “butt” to the welding surface, in other words, using a very short arc, you need to use maximum and average currents without using oscillatory and transverse movements. This distance is excellent for making root welds in almost all types of joints and in different positions.

The distance between the surface of the part and the welding electrode is approximately 50% of the diameter of the electric current conductor. Welding at such a distance, as a rule, increases the welding current and the depth of penetration of the base metal.

The tension and seam width are significantly reduced. The weld pool is perfectly protected.

One of the answers to the frequently asked question: how to properly hold the electrode when welding a vertical seam is that a short arc is applicable during vertical welding, as well as for making ceiling and horizontal seams.

"Note!

A feature of the average arc is the distance between the electrical conductor and the surface of the part from 1 to 1.2 times the diameter of the electrode used. By maintaining such a distance, the tension increases and the seam expands significantly.”

Using a long arc of 150% of the electrode diameter, most often, the seam is wider, the penetration depth is reduced, and the protection of the bath is significantly reduced. Strong spattering of the electrode metal may occur, resulting in the formation of pores in the weld.

Welding mode selection

By mode is meant a set of aspects to create the normal course of the welding procedure. It directly depends on the angle at which you hold the electrode when welding, and also affects:

welding conductor diameter;
current characteristics (type, polarity, magnitude);
initial temperature of the base material;
polarization of electrodes;
welding arc length;
voltage;
moving the end of the electrode.

An increase in current can cause, at a constant speed, an increase in the penetration depth, which is characterized by a change in the value of the linear energy. And also by changing the pressure indicator exerted by the arc column on the weld pool.

Indicators of polarity and type of current affect the appearance and size of the seam.

The width of the seam also directly depends on the value of the stress parameter. The higher it is, the wider the seam.

The diameter of the welding conductor is selected depending on the thickness of the material being welded, the position in which the welding is performed, as well as the characteristics of the connection and the shape of the prepared edges for welding.

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Welding modes also depend on the position of the electrode and the part being welded.

Conclusion

The welding process is designed to produce permanent joints of metal elements using local heating until plasticity and melting. It is widely used in the construction and industrial industries for the manufacture of various metal structures, reinforcing cages in reinforced concrete products.

The welding process significantly reduces labor costs during the production of metal structures, ensures reliable connection of elements and saves metal. The quickest way to figure out how to hold the electrode correctly when welding is to watch a video with lessons from specialists and a detailed description of the process.

Source: https://svarkaipayka.ru/material/elektrodyi/kak-derzhat-elektrod-pri-svarke.html

How to cook by welding | Do it yourself

Modern electric arc welding is easy to use and does not require expensive equipment. Skills in working with a welding machine will be useful both in construction and in repairs related to metal structures. The main advantage of this method is the ability to correct mistakes at any time, cut the product and weld it again.

We will need: a welding machine, electrodes, protective gloves (gaiters), protective clothing, a welding mask with a chameleon filter.

Selecting a welding machine and electrodes

There are several types of welding machines, but only two are relevant for amateurs: a transformer and an inverter. We recommend choosing an inverter with a capacity of 150 to 200 A. “Universal” 2–4 mm electrodes are suitable. There are also specialized electrodes, but they are of interest only to professionals.

How to cook correctly - instructions

Before you begin, it is advisable to clean the edges of the product from rust and paint; this is a feature of arc welding. If possible, secure parts of the product.

How to install the electrode and set the current strength?

Electrodes must be dry and free of defects. The current strength must be selected depending on the thickness of the electrodes. Recommendations should be on the packaging with them and on the welding machine itself. It is not difficult to calculate the range of minimum and maximum values; you need to multiply the diameter of the welding electrode by 30 and 40 (for example, the optimal current strength for an electrode with a diameter of 3 mm will be a working range of 90–120 A).

How to light an electric arc?

Turn on the device. As shown in the video, you need to scratch the electrode on the metal until an arc appears. In order not to lose it and not to burn the metal, the welding electrode must be kept at a distance of 3–4 mm from the surface. It will burn as you work and flow into the weld, you need to monitor this process and maintain a distance.

How to weld a seam?

You need to start welding from the edge of the product. There are more than a dozen techniques for guiding the electrode along the seam. The simplest is small circular movements, as shown in the video. Note! The part must be melted to its full depth, along both edges. You cannot allow only one edge to melt.

The electrode is stuck to the metal. What to do?

The main thing is not to try to tear it off by force! You just need to move the electrode from side to side, as the master shows - it will easily come off. As you can see, electric welding is easy. Good luck with your work.

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Source: https://sdelairukami.ru/kak-pravilno-varit-svarkoj/

A manual for dummies: features of arc welding with electrodes

Electrode welding is an electric arc welding method used to join metal products. This method gets its name from the welding arc - a long flow of energy that occurs in the electrode when welding metal at high temperatures.

A conductor (electrode) is a metal wire with a special coating, which is an inert medium during the operation process. It typically consists of limestone, alumina, magnesia, nickel, iron and manganese.

Next, we’ll look at how to weld metal correctly, without defects or flaws.

Features of electrode welding

In addition to learning how to weld properly, you need to know that it has a number of advantages and disadvantages. The quality of work directly depends on the equipment. The more expensive it is, the more powerful and better quality it is. Hand-held devices must perform the following functions:

connect parts even in hard-to-reach places:
have the ability to weld in all positions;
weld all types of metal.

In addition, this device also has some disadvantages:

low efficiency compared to other technologies;
the quality of metal joining directly depends on the skill of the welder;
During operation, harmful fumes and sparks arise that negatively affect vision.

Regarding the last point: electric arc welding requires a special uniform for the operator and the use of special glasses and a “chameleon” mask, which protects vision, but at the same time provides good visibility.

Arc welding technology

Electric arc welding is performed using a specific technology to ensure a good, smooth and durable connection of products.

There are several ways to ignite an arc:

spot, in which the welder precisely hits the product with a conductor;
striking method.

The properties of conductors may also differ with different ignition methods. This is due to the coating on it. Some are easier to set on fire, some are more difficult, but each type of material has its own advantages and disadvantages.

Creating an arc with a new electrode is much easier. It is enough to touch the metal with it and immediately lift it to a distance of 2-3 millimeters. When a conductor is repeatedly ignited, a slag film appears at its end. In this case, you need to point the material several times until a spark is formed.

The arc length is a value that indicates the gap between the electrode and the parts between which the electrical discharge occurs. This indicator directly depends on the diameter of the electrode and is selected from 0.5 to 1.2 of its diameter. To obtain a high-quality seam, the electrode must be kept as close to the part as possible.

Preparatory stage

Before you weld metal with electrodes, you need to prepare everything. First, connect the device. Secondly, clean the parts and secure them securely so that they do not “walk” under the device. Third, the welder must wear a protective mask.

To begin with, it is recommended to practice how the material is ignited on metal in order to get an idea of which method will work best.

Arcing

When welding for beginners, it is recommended to maintain a short arc to create a perfect path, without flaws. You won't be able to do it the first time - you need to practice for a while.

The shorter the arc, the fewer metal drops it produces and the easier it is to create high-quality fusion. In this case, the conductor melts evenly and smoothly, providing sufficient penetration depth. A beginner can control the length of the arc by the sound of the equipment. When short it is uniform, when long it is loud and sharp.

Theoretically, everyone knows how to weld metal, but in practice it takes a long time to learn how to create a high-quality arc. If it breaks, it needs to be re-excited and the gaps in the seams “soldered”. The quality of the arc depends on the current strength, and the quality of the seam depends on it.

If you use the wrong approach, you can cause a burn on the product, where the material will subsequently begin to deteriorate.

Seam formation

To join metal by electric welding, it is important to create a reliable and high-quality alloy between the materials. There are several types of basic seams:

Thread is the easiest way that even a novice craftsman can create. It is characterized by longitudinal translational movements and a width of no more than 3 mm. It does not create a secure hold and can be used on thin and insignificant parts. It is recommended to start training with this path for young masters, in order to then move on to more complex technologies.
The longitudinal-transverse type is created in accordance with the name. That is, in this case, you need to have the knowledge and skills of how to correctly guide the electrode in several directions - vertically and horizontally. This track is much stronger than the previous one. It is durable and has a width of 1-1.5 centimeters. The most common technology for such a seam is a zigzag, in which the conductor is drawn from edge to edge 10-15 mm in each direction. At the same time, it is very important to maintain the arc length in order to obtain an ideal path with minimal slag impurities.
When the working element moves in three different directions, a strong, “dead” and reliable seam is created. Initially, it begins as a longitudinal-transverse one, but then you need to create return movements that allow you to re-work the welded line for greater reliability of fastening the materials. Here it is necessary to hold the device correctly, otherwise, if the slope is too large, the connecting track will turn out to be thick and uneven.

Upon completion of the work, it is imperative to knock off the slag from the joint in order to leave a perfectly even weld strip. If done incorrectly, the path will be uneven, with gaps and deformations. In addition to the aesthetic appearance, such quality of cooking may affect the further operation of these products.

Review of the main mistakes made by beginners

How to properly cook by welding - we figured it out. According to standards, main errors are divided into 6 criteria:

discrepancy in size and shape;
the presence of voids and cavities;
cracks;
uncooked areas;
solid inclusions;
other defects.

To ensure that everything works out quickly and efficiently, we suggest that you familiarize yourself with the most common metal welding mistakes that beginners make:

Choosing the wrong arc length is the most common mistake made by beginners and not very experienced craftsmen. With a short length, the fusion surface is uneven and too rough. In this case, the seam is of poor quality due to the high content of slag. When the arc, on the contrary, is long, the welding is uneven, with a large number of sprayed drops of metal. In addition, the large distance between the electrode and the part contributes to arc instability, which causes “gaps” in the seam.
Incorrect machine control speed. When the conductor moves quickly, an uneven roller is obtained that contains a lot of slag. Such electric welding will not last long, since it is believed that the part is poorly welded due to the thinness of the seam. If you move it too slowly, the roller becomes thick and bulky.
The settings on the device are not set correctly. It is important to set the amperage according to the type of workpiece and conductor size. With low amperage, the road will be thin and uneven, resulting in incomplete fusion. As for the excessively high voltage, the track ends up flat and dense, containing a large amount of slag.
Poor surface preparation. Insufficient cleaning of paint residues, oil, grease or dust leads to “gaps” and uneven paths. As a result, the strip will be flimsy, which will lead to deformation of this product in the future.
The angle of the conductor also plays an important role in creating a tight and reliable connection. With a strong inclination relative to the horizontal, an uneven path with sharp scales is obtained. If you place it too straight, that is, perpendicularly, then the scales turn out to be too dense and create a high roller with a large amount of slag.

In addition to the technical shortcomings described, often the result of unsuccessful alignment is a faulty machine, mismatch between current and material, improperly prepared work surface and other welding rules that should be taken into account.

In conclusion, it is worth noting that when using electric arc welding, a number of criteria must be taken into account, on which the result will depend. The most important thing is to create a high-quality and even seam. To do this, you need to know how to weld metal correctly and harmoniously combine several factors:

amperage;
electrode type;
tilt of the work product;
arc height;
speed of movement of the device.

If all criteria are fully met, you will get a high-quality one-piece fusion that will last for many years without breakage or deformation.

Welding technology is the basis that needs to be thoroughly studied. It is recommended to begin practice when the novice master is fully familiar with the theoretical foundation. And knowing how to weld metal correctly, all that remains in practice is to hone your skills.

Source: https://svarkaed.ru/svarka/obuchenie-svarke/svarka_elektrodami.html

How to insert the electrode correctly

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.

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.

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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.

Welding technology

For an electric arc to occur, two conductive elements with opposite charges are required. One is a metal part, and the second is an electrode.

The electrodes used for manual arc welding consist of a metal core coated with a special protective compound. There are also graphite and carbon non-metallic welding electrodes, but they are used for special work and are unlikely to be useful to a novice welder.

When an electrode and metal of opposite polarity touch, an electric arc occurs. After its appearance, in the place where it is directed, the metal of the part begins to melt. At the same time, the metal of the electrode rod melts, being transferred with the electric arc to the melting zone: the weld pool.

How a weld pool is formed. Without understanding this process, you will not understand how to weld metal correctly (To enlarge the size of the picture, right-click on it)

During the process, the protective coating also burns, partially melting, partially evaporating and releasing a certain amount of hot gases. Gases surround the weld pool, protecting the metal from interaction with oxygen. Their composition depends on the type of protective coating. The molten slag also coats the metal, also helping to maintain its temperature. To weld properly, you must ensure that the slag covers the weld pool.

The weld is formed by moving the bath. And it moves when the electrode moves. This is the whole secret of welding: you need to move the electrode at a certain speed. It is also important, depending on the required type of connection, to correctly select its angle of inclination and current parameters.

As the metal cools, a slag crust forms on it - the result of the combustion of protective gases. It also protects the metal from contact with oxygen in the air. After cooling, it is beaten with a hammer. In this case, hot fragments fly away, so eye protection is required (wear special glasses).

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.

Start of welding: light the arc

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.

Source: http://gidpotolok.ru/info/kak-pravilno-vstavit-jelektrod/

Correct position of the electrode during welding

The correct position of the electrode during welding is one of the main conditions for obtaining a high-quality, reliable joint.

Depending on the type of connection, the electrode must be held and tilted differently, so it is important for a novice welder to learn how to maintain an optimal position in relation to the surface of the parts being welded. The inclination of the electrode during welding affects the heating of the part and the maintenance of molten metal in the weld pool.

Basic Rules

To strike the arc, the electrode must be held at a right angle, then tilted a small degree (about 15 °). The distance from the surface is 1-2 mm. To obtain a high-quality joint, it is necessary to weld with a shorter arc.

When the electrode is positioned perpendicular to the base metal, it quickly spreads in the weld pool and fills all the voids with the melt.

To reduce the heating of a thin metal plate, it is necessary to place a seam with a small leg. As the angle decreases, heat transfer increases, and the welding speed in this case will decrease. It becomes possible to form a high-quality roller.

If the angle of inclination of the electrode is very sharp, then the material of the main structure will not heat up. The weld pool is quite narrow. The seam will be high, but with uncooked edges.

To achieve a permanent connection of well-fitted parts, during a butt connection it is necessary to maintain uniform advancement of the electrode at a constant angle of inclination.

This method helps fill the weld pool with filler metal and form a weld with increased density.

But in some cases it is necessary to change the angle of the electrode, for example, when welding pipes. It is especially important to follow this rule for welding non-rotating joints.

To fill all the voids in the weld puddle, it is sometimes better to make the slope sharper, slowing down the filler metal filling of the weld and maintaining the selected leg. When finishing the passage, you must remember to lift the tip of the electrode so that a crater does not form.

The ability to hold the electrode correctly during the welding process comes with experience. You must constantly remember the location of the core and try to hold the holder handle without tension. Your hands should be slightly relaxed and your movements should be free.

Technique

If you follow the rules of welding, you can smooth out errors arising from deviations in the angle of inclination of the holder. Depending on the required filling of the weld, several methods are adopted:

triangle. This wiring allows you to reliably weld the root of the seam. It is used for welding parts with a thickness of over 6 mm and provides reliable heating of the middle part of the seam. The method is most common when welding pipes with a fixed joint;
guiding the electrode along a broken zigzag line. It is used when welding structures with a metal thickness of less than 6 mm. The highest quality seams are obtained when butt welding and in the lower position. Such wiring can be used to weld joints efficiently without ensuring bevel of the edges;
circular or elliptical movements with the electrode. This method ensures reliable heating of both planes of the parts being welded. It is used when welding structures made of alloy steels and in a vertical position of the joint.

In this case, it is important to ensure simultaneous advancement of the core together with the movements responsible for heating the joint and filling the seam. There are three promotion options that can replace each other.

The first option is translational movement along the axis of the core. This movement is necessary to maintain an arc with a constant length and ensure a certain speed of welding structures.

The second type is movement along the axis of the seam in a straight line. In this case, the welder has the opportunity to control the time of metal melting and provide a certain leg.

The third option is to make oscillatory movements at an angle of 45° across the seam. This method is used to ensure heating of the edge of the part.

The welder can adjust the width of the bead on thin metal. This option for advancing electrodes is indispensable for multilayer joints . Used for root seam.

Selecting the angle of inclination

It is necessary to move the electrode at different angles. The choice of the desired position depends on the type of material, the location of the parts in space and the thickness of the metal. The main methods of core management include three methods.

Angle forward

In this case, the core is driven at an angle from 30° to 60°. In this position of the electrode, the molten coating forms slag.

It moves after the weld pool and reliably covers it from the invasion of harmful gases. Some slag that falls in front of the weld is displaced by molten metal on the sides of the joint.

If a large amount of slag forms in front of the bath, then the slope must be reduced. In rare cases, the tilt can be adjusted to a right angle. This must be done when there is severe slag formation.

In this case, it does not have time to harden and fills the bath, extinguishing the welding arc. Therefore, it is necessary to ignite the arc at a right angle, gradually changing it, to achieve normal slag formation.

This method is used when a small depth of heating of the base metal is necessary, for welding ceiling joints, welding a vertical seam on a channel, welding pipes with a fixed joint and for making a root weld on thick metal workpieces.

Perpendicular

It is quite difficult to constantly hold the electrode perpendicular to the surface, so the method requires sufficient skills as an electric welder.

Used for welding in inaccessible places where it is not possible to tilt the electrode at a different angle. In this case, you can achieve a small penetration of the metal parts.

Angle back

Welding is performed with an inclined electrode, similar to when welding with a “forward angle”, only the angle is counted in the other direction. In this case, the molten slag is forced out of the weld pool and is located immediately behind it.

For different electrodes, it is necessary to select a certain angle that will ensure optimal performance of work. The molten slag must have time to pass immediately behind the electrode and cover the molten metal, ensuring its uniform cooling.

This method is most often used when welding with the condition of reliable molten metal, regardless of the thickness of the structural parts. This method is indispensable when welding cores with rutile coatings.

Used to make the first (root) seam of thick parts in a vertical or lower joint position. This method will provide a reliable permanent connection of angular joint positions, channel welding, and pipe connections. For a more experienced electric welder, welding with a very small welding arc is possible.

Regardless of the choice of method for tilting the electrode during welding, the position of the slag in the weld pool should be maintained in balance. It should not spread quickly in front of the seam, but it should not lag too far behind it.

In any case, choosing the right angle and holding the electrode stably during electric arc welding is possible only with experience.

Source: https://svaring.com/welding/teorija/kak-pravilno-derzhat-elektrod-pri-svarke

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