History of the origin and development of welding
The history of the development of welding can be traced back to ancient times. The earliest examples of bonded metal are ancient bronzes. It is estimated that some items were made more than 2,000 years ago.
During the Iron Age, the Egyptians and people in the eastern Mediterranean learned to weld pieces of iron together. Many instruments have been found that were made around 1000 BC. e.
In the Middle Ages, the art of blacksmithing developed; many iron products were produced, connected by the process of obtaining permanent joints with a hammer. The history of welding suggests that until the 19th century, the joining process as we know it today using gas or electricity was not used.
The first semblance of electric welding
The production of an arc between two carbon electrodes using a battery is credited to Sir Humphry Davy in 1800. In the mid-19th century, the electric generator was invented and arc lighting became popular. For the first time, the idea of the arc lighting process was developed by Professor V.V. Petrov was used for welding metals. The invention of combining metals using gases did not stop either. Edmund Davy of England is credited with the discovery of acetylene (the reaction of potassium carbide with water) in 1836.
19th century French electrical engineer Auguste de Meritan used the heat of an arc to join lead plates for storage batteries while working in a laboratory in 1881.
His student, Russian engineer Nikolai Nikolaevich Benardos, working in the same French laboratory, made his contribution to the history of the development of welding by receiving a patent for the invention of this compound. Together with the Russian engineer Stanislav Olszewski, he also received a British patent in 1885 and an American patent in 1887.
The patents also included an electrode holder. This was the beginning of carbon arc welding. Carbon arc jointing became popular in the late 1890s and early 1900s.
The history of the development of welding marks the inventor of electric arc welding as the Russian engineer Nikolai Nikolaevich Berandos (1842-1905).
In 1882, Russian engineer N.N. Benardos introduced a new method into the history of welding development, in which carbon electrodes were used.
Application of electrodes
In 1888, Russian engineer Nikolai Gavrilovich Slavyanov first used electrodes, the design of which included a metal rod under a layer of flux. In the presence of a state commission, he managed to weld the crankshaft of a steam engine.
This idea of electrode coating evolved. Engineers proposed a thin coating of clay or lime that would provide a more stable arc. Oskar Kjellberg from Sweden invented a coated electrode with a mixture of carbonates and silicates.
Meanwhile, welding processes have evolved to include spot, seam, projection and butt welding. In 1903, a German named Goldschmidt invented thermite welding, which was first used to join railroad rails.
Gas cutting was also improved during this period. The production of oxygen and then the liquefaction of air, along with the introduction of the blow tube or burner in 1887, helped develop this field. However, around 1900 a burner suitable for use with low pressure acetylene was developed.
The First World War brought a huge demand for the production of weapons and the history of the development of welding was in demand for the production of weapons. Many companies have emerged in America and Europe to produce welding machines and electrodes as per the requirements.
Alternating current was not invented until 1919 and did not become popular until the 1930s when mass production of electricity began. After this, the electrode with the necessary coating found wide use.
In the 1920s, various types of welding electrodes were developed. During the 1920s, there was considerable debate about the merits of metal-coated and non-metal-coated rods made by extrusion (grinding).
During the 1920s, significant research was carried out into shielding the arc and welding zone by externally applied gases. An atmosphere of oxygen and nitrogen in contact with molten weld metal caused brittle and sometimes porous welds. Engineers used hydrogen as a welding atmosphere.
Hydrogen was replaced by atomic hydrogen in the arc. Atomic hydrogen was formed by exposure to an electrical discharge. This arc produced twice the heat of an oxygen flame.
Atomic hydrogen never became popular, but was used in the 1930s and 1940s for special tool steel applications.
In 1932, for the first time in the world, underwater welding was carried out in the Soviet Union.
Engineers H. M. Hobart and P. C. Devers carried out similar work, but used an atmosphere of argon and helium gases. In its patents filed in 1926, gas arc welding was the harbinger of a new process.
In 1953, Professor Lyubavsky and assistant Novoshilov announced the use of welding with consumable electrodes in a CO2 gas atmosphere. The CO2 process immediately gained popularity due to the fact that it used already developed inert gas equipment. This variation soon became the most popular arc welding technology.
Another option is to use an inert gas with a small amount of oxygen, which provides a stable arc.
How does today's conventional household welding work?
Briefly, how today's ordinary household welding works: electricity is supplied to the electrode and the welded product to create and maintain an arc from a special device.
Under the influence of the arc temperature, the edge of the metal being welded and the metal from the electrode begin to melt.
Due to the fact that all the metals involved are melted, they mix together to form a strong bond, while at the same time the molten slag floats to the surface, which forms a protective film. After the metal hardens, a weld will be formed.
1882 - Benardos created the first welding method using carbon electrodes.
1888 - Slavyanov first used electrodes, the design of which included a metal rod under a layer of flux. In the presence of a state commission, he managed to weld the crankshaft of a steam engine.
1939 - Paton figured out how to automate submerged arc welding, welding fluxes, tank turrets, and the first bridge made of welded elements.
Today's development of science and technology has made it possible to use fundamentally new ways and methods of joining metals.
Source: https://v-nayke.ru/?p=1698
History of welding development. Scientists and their discoveries in the field of welding
The history of the emergence of any modern technology cannot be considered in isolation from generally known historical processes and generally accepted names of historical periods. Any technology initially has prerequisites for its emergence, a process of development through the prism of history, culminating, significant names of scientists, a result in modern times and prospects for further development.
The welding process, no matter how modern it may seem at first glance, appeared around the 8th-7th century BC. To create more and more advanced tools, people began to change the shape of metal, which existed on its own in nature, and also tried to connect small pieces of it. These metals included copper or gold. They did this only with the help of stones and physical strength. This process was the first type of cold welding.
A little later, man learned to independently mine other types of metals (copper, lead, bronze), and also to produce larger products using heat treatment - heating individual elements. Casting was already used to produce almost perfect products.
The Iron Age is characterized by the fact that people learned to mine iron. This mark appeared on the time ruler about three thousand years ago. The process of iron mining now looks very simple: iron is separated from natural iron ores by smelting. But in ancient times it looked different, since no one knew how to melt.
A certain mixture with only iron particles was obtained from iron ore. In addition, this mixture contained non-metallic impurities: coal, slag, etc. Only after a significant amount of time, by forging the heated mixture, was it possible to separate the iron from everything else.
The result was iron blanks, which were subsequently forged welded into amazing products: tools and weapons.
The most advanced technologies in the welding process until the Industrial Revolution were only forge welding and brazing. The latter was widely used in the field of jewelry production.
Fundamental discoveries
A breakthrough in welding technology was made during the industrial revolution or industrial revolution. Discoveries in the field of electricity were made over the centuries, which ultimately led to the following.
In 1802, the Russian physicist Vasily Vladimirovich Petrov discovered and, as an experimental physicist, proved the possibility of using the electric arc in practice. This discovery is considered the most outstanding success of the scientist. It is the main prototype of modern welding devices. He outlined all the conclusions of his discovery in the book “News of Galvanic-Volt Experiments,” published in 1803. However, at the time of its opening, no one was particularly interested in it.
V.V. Petrov. Russian experimental physicist, academician of the St. Petersburg Academy of Sciences, inventor of the electric arc
Sir Humphry Davy conducted research with the electric arc in 1821. His student, Michael Faraday, devoted a lot of time to studying the connection between electricity and magnetism. In the 1830s he discovered electromagnetic induction.
A little later, the electric arc began to serve for the benefit of society when it appeared in household lighting lamps.
Only in 1881, Nikolai Nikolaevich Benardos, a Russian engineer and inventor, came up with the electric arc welding “Electrogefest”. After several years of improving the invention, in 1887, it was patented, and a few years later it spread not only throughout Russia, but throughout the world.
Postage stamp with the image of N.N. Benardos in honor of the 100th anniversary of the invention of electric welding
In 1885, Bernados opened the Electrogefest partnership, which had the first welding workshop. Benardos received a patent for his invention for the first time. The scientist spent his last savings on obtaining this patent in Russia; European countries issued the patent with the help of funds raised from the merchant Olshevsky.
After the worldwide spread of the electric arc welding method and worldwide recognition, Benardos developed electric arc welding with carbon and metal electrodes. He became the founder of the idea of the electric arc welding process with a metal electrode using alternating current; inclined electrode welding; technicalization of the welding process.
Thus, all of the above scientists and inventors are considered the founders of welding, those who invented it.
Despite such key discoveries in the field of electric welding, the 14th century is not famous for its extensive and widespread use, since electricity was in short supply. It was problematic to apply all the new discoveries, but no one was going to refuse to use them. The transformation of welding equipment and welding machines continued.
The year 1904 was marked by the appearance of cutters. The years 1908-1909 are characterized by the emergence of underwater metal cutting technology. It began to be used in France and Germany.
Gas welding occupied a leading position in welding production until the 30s, and was intensively used during the First World War. The Baku-Batumi and Grozny-Tuapse main pipelines were built using gas welding.
The construction of pipelines was carried out using only gas and gas press welding processes.
Construction of the Baku-Batumi oil pipeline
Electric arc welding was not so widespread in those years due to the fact that its power source required improvement (the length of the arc was short and it burned unstably). This problem was addressed in the period from 1914 to 1917. allowed by such scientists as Stromenger, S. Jones, Andrus and Stresau, each of whom contributed to the creation of a coating for the welding electrode to make it easier to maintain the arc.
Modernity
Let us briefly outline the types of modern welding process.
Electric arc welding.
Currently it occupies a leading position among other species. Today it is the most common, accessible and cheap.
Electroslag welding.
The most advanced process in the field of welding large parts, such as ship construction, load-bearing structures, boilers, rails, etc. The fundamental principle of this type of welding is that an electric current is passed through the slag. Slag is formed when flux melts, and it is also a conductor of electric current. As an electric current passes through the slag, heat is released.
There are the following types of electroslag welding:
- three electrode wires;
- large cross-section electrodes.
The essence of electroslag welding
Contact and press welding.
Resistance welding is the oldest. Founder: William Thompson. Initially it was distributed in the USA, after which it began to be used in Russia. This was accompanied by an increase in the volume of research activities in this area in Russia: factories and combines “Orgametal” (TsNIITMASH), “Electric”, “Institute of Electric Welding named after. E.O. Paton", Moscow Higher Technical University named after. Bauman, VNIIESO and others.
Contact welding is divided into:
- Butt (connecting parts along the entire plane of their contact by heating);
- Point (parts are connected at one or several points simultaneously);
- Relief (elements are connected at one/several points with special protrusions-reliefs);
- Suture (connecting elements with a seam).
contact welding
Pressure welding or pressure welding is the joining of metals without melting them (solid surfaces), only with deformation using force. This type of welding came to us straight from antiquity with its cold welding.
Gas welding and cutting.
Gas welding is a process of melting metal using special torches in which flammable gases are burned. The first gas burner was invented in France at the end of the 19th century. It worked on a mixture of oxygen and hydrogen.
When cutting metal, it occurs by “burning” the metal in a stream of oxygen.
Beam types of welding.
Modern research by scientists in the field of optics and quantum mechanics makes it possible to identify completely new types of beam welding based on the energy of ion and photon rays. The following types of beam welding are distinguished:
- Electron beam (heat source is an electron beam; the welding process takes place in a special installation: in vacuum chambers);
- Laser (heat source – laser beam). This type is distinguished by the following features: environmental safety, lack of mechanical processing, high welding speed, and the significant cost of laser systems.
Laser welding
- Plasma welding (heat source is a plasma jet, that is, an arc produced using a plasma torch). The plasma torch can be of direct or indirect action.
Prospects for the development of the welding process
Prospects for the development of welding production arise from the current disadvantages or problems of existing and used types of welding. Today, the most experienced scientists and equipment developers are working hard on any shortcoming to make human life and production even easier.
The first thing that improvement is aimed at is the creation of welding machines that are fully or partially automatic. In the future, such a move will increase the efficiency of the welding process and increase the power factor.
The second is the ability to remotely control and regulate the welding process of large-sized and complex elements of a single structure (highways, industrial facilities, etc.)
Third, finding a way to reduce the cost of laser welding, as was once done with electric arc welding.
Another problem is the fact of creating high-quality and durable welded structures that are capable of functioning not only in normal conditions, but also in conditions of sharp temperature changes, under water and even in outer space, which is very important today.
Currently, the welding process as a whole is being computerized. Computerization refers to the introduction of computer technology capabilities into the main areas of engineering activity in the field of welding: scientific research, preliminary design, management and control of technological processes.
It is important not to overlook the importance of information in welding. Having the right information, at the right time and in the right place, only increases the opportunity to make truly important discoveries. Information must be accessible, open and understandable. This requires unified systems and databases with the necessary reference and bibliographic information for all interested parties.
It is obvious that welding is a unique process that has no analogues. The beginning of development occurred before our era, and this process has not stopped to this day. Given the need for this unique technology, a number of scientific studies are being conducted. It can be said with certainty that the process of development of new types of welding will not be long in coming, since technology in our time is improving at an incredible speed.
Source: https://svarkaed.ru/svarka/poleznaya-informatsiya/istoriya-razvitiya-svarki-uchenye-i-ih-otkrytiya-v-oblasti-svarki.html
The first welding machine - History of welding development. The role of welding in the modern world
The history of the development of welding goes back to our era. Ever since people learned how to mine metal, they have strived to create something useful from it. The most reliable connection method is the hot method. Now it is difficult to imagine that two centuries ago Russian scientists stood at the origins of modern welding machines.
Since then, a new page in the life of humanity began. Now there are several types of welding technologies used in production and at home. The modern history of welding is the invention of new units, methods of joining metals, and personal protective equipment of a new generation. But the traditional arc method using molten and refractory electrodes remains popular. Welders create huge metal structures and miniature works of art.
The role of welding in the modern world
Laser welding methods are currently being developed. A technology for high-precision metal joining has been developed. New composite materials are appearing; the use of aluminum, stainless steels, and non-ferrous metals is widespread. The following types of high-temperature metal compounds are widely used:
- argon-arc technology makes it possible to obtain all types of connections: butt, corner, T-joint, overlap;
- gas, with its help, main pipelines are created that run far from power sources;
- semi-automatic allows you to speed up the process of joining elements, has high accuracy, and reduces the risk of a poor-quality seam;
- Traditional manual electric arc always remains in demand.
Power sources are changing, holders are being improved, but the principle of hot joining of metals does not change. The welding method is preferable to other types of connections due to a number of advantages:
- due to saving metal;
- wear-resistant equipment has a large margin of safety and is used in any conditions;
- compounds are formed at the molecular level with high strength.
First mentions of welding
Long before the advent of welding units, there were other ways to join metal. Samples of compounds created in the 8th – 7th centuries BC have been found. Native gold, pieces of copper and meteorite alloys were used for household purposes and weapons. They were held together by heating using a method comparable to forging.
The stage of the emergence of casting is the next page in the history of welding technology. The gaps between the parts of the metal were filled with melts, creating something like seams. When low-melting metals were discovered, they began to be used to join metals, and soldering arose. Soldering and forging technologies were used before the discovery of the electric arc method, until the end of the 19th century.
Opening the electric arc
Vasily Vladimirovich Petrov
Physicist and electrical engineer, academician Vasily Petrov discovered the electric arc effect in 1802. During his experiments, he passed an electric current through a metal and carbon rod and noticed that a bright flash appeared - a high-temperature arc. His works contain a description of this phenomenon. But before the discovery of the welding machine, there were years when electrical engineering was developing. Arc technology required powerful current sources.
Nikolai Nikolaevich Bernados
Russian inventor Nikolai Benardos developed electric arc welding only 80 years after the discovery of the arc. A new stage in the history of welding development has begun. Nikolai Nikolaevich used an arc for cutting and joining metal elements.
A few years later, Nikolai Gavrilovich Slavyanov created the first welding machine and electrodes. He is an official author recognized throughout the world. For the first time, it was he, a Russian engineer, who invented welding and patented it, only then did technologies begin to develop in other countries.
Slavyanov actively promoted his method:
- corrected defects that occurred during casting of parts;
- restored parts of steam turbines;
- welded worn parts.
Slavyanov Nikolay Gavrilovich
He developed fluxes that protect the hot seam from oxidation, and invented a welding generator with adjustable power. The introduction of his inventions was carried out abroad. Welding began to be used everywhere.
Development of technology in modern times
The next stage of history is connected with the Paton surname. My father organized the first welding institute in 1929, under his leadership the technology of welding processes developed. During World War II, new methods were used in the defense industry. New types of fluxes and electrodes for thick-walled products were developed. They were used in the production of military equipment: tanks, guns, bombers and their equipment.
Evgeniy Paton
The Kiev Institute developed a method of powder, resistance and slag welding in a liquid and rarefied environment; inert gases were used to protect the seam. The work of Evgeniy Paton was continued by his son, Boris. He headed the welding institute after his father left. Space laser welding technologies were developed under his leadership. Methods of joining metals under water have become more widely used. This technology is used in ship repair docks. The method reduces ship repair time by 1.5 times.
Prospects for the development of the welding process
Currently, traditional methods have replaced laser methods. They are predicted to have a great future. The process can be controlled remotely. Robots are replacing welders. A device has been developed for automatically supplying filler material to the weld zone; a thin beam that melts the metal is adjusted with high precision.
The second direction in the development of high-temperature metal joining technology is the use of fiber optic materials. This will increase the efficiency of power equipment: generators, converters. The output current power will gradually increase, now the maximum is 6 kW, it is planned to increase it to 25 kW and higher.
Laser technology will gradually replace the gas welding method. Flexible modules will be created that can be used in any weather conditions. The labor intensity of technological processes will be reduced, and new methods of quality control for high-temperature metal joining will be developed.
Source: https://ice-people.ru/raznoe-2/pervyj-svarochnyj-apparat-istoriya-razvitiya-svarki-rol-svarki-v-sovremennom-mire.html
Who invented the welding machine
Welding plays an important role in the construction of buildings, the creation of cars, and the production of various metal products. Water is delivered and waste is removed through pipes welded with an electric arc and coated with electrodes.
Heating, doors, stairs and railings are also often made using welding using various devices. Without this, humanity would be in the distant past in terms of advanced designs and communications.
But when did the history of welding begin? Who was the first to discover the phenomenon of the electric arc and understand what opportunities it provides? How have equipment and technologies improved over time?
Achievement of humanity
The welding method of joining metals has made a real revolution in the world of industry and construction, speeding up the creation and increasing the strength of many structures. We are talking about exciting an electric arc between two contacts connected to the poles of the device. The arc, when heated, melts the edges of the metal, creating a common “puddle” of molten iron. This is how the sides are joined into a single alloy.
To increase the strength of the weld, a consumable material is used, which can be in the form of an electrode rod, or as an additional filler wire.
This way you can perform not only welding, but also surfacing of worn parts.
The difficulty was in creating a safe method, because an electric arc can also occur at high voltage, but holding working parts with a high volt value is very dangerous for human life.
The process went further when scientists were able to create step-down current sources, where, thanks to the principle of electromagnetic induction, the voltage was significantly reduced, and the current strength, on the contrary, increased. This made it possible to secure the welding process, and the increased current made it possible to melt thicker sides of the metal. Next, scientists concentrated on modernizing the electrodes and working elements in the hands of the welder.
Great efforts were also made in the field of protecting the weld pool from external gases. If you make a seam with a bare metal rod, the arc will burn, but the subsequent bead of metal will be completely riddled with pores of retreating carbon.
To create a strong, hermetically sealed connection, it was necessary to develop various coatings for the electrodes and special flux powders that prevent the interaction of molten metal and the surrounding air.
But people did not come to this right away, and the history of the development of welding begins in ancient centuries.
The very first manifestations of welding
Even during excavations in ancient Egypt, gold jewelry was found that was soldered together with tin. Light alloy material heated over coals was applied to gold jewelry and solidified to form some kind of compound.
During excavations in Pompeii, archaeologists found the remains of water pipes that had transverse seams on lead pipes. Since lead also melted easily over fire, it lended itself to pouring into molds and creating joints.
Some metals were combined in forges. The sides were heated over coals to a plastic state and knocked together with blows of heavy hammers. This compression provided reliable adhesion of materials.
This found application in the creation of artillery hulls mounted on ships. Partially they were poured into molds, and partially connected by forge welding and additional framing with clamps.
But humanity's capabilities were limited by the temperature of the coals. Therefore, other metals for joining were not available.
Rapid development of technology in the 20th and 21st centuries
Since the beginning of the 20th century, inventions in the field of welding began to be differentiated into subcategories based on the equipment used. The developers realized that not only an electric arc can melt metal, but also an acetylene flame can reach temperatures of up to several thousand degrees.
For this purpose, the acetylene generator was developed in 1906. Their design is very similar to modern models and consists of immersing the carbide in a liquid, where oxidation promotes the decomposition of the solid material and the release of pure acetylene. Pressure is built up in the chamber and gas is transferred through a hose to the burner.
In 1903, two French developers proposed a practical design for a welding torch with a mixing chamber. Acetylene was supplied through one channel, and oxygen through the second, which “accelerated” the temperature of the torch to 3000 degrees. This has found wide application in welding water and gas pipelines.
In parallel with this, electric welding continued to develop, the history of which dates back to 1912, when it was decided to produce electrodes with a thick coating. This gave several advantages:
- better protection from the external gas environment;
- stable arc burning;
- denser seams, similar in structure to the base metal;
- Possibility of use on ships and in industry.
Since 1940, welding with a tungsten electrode in a protective gas environment has become available to the world. Initially it was helium, but now argon is also used.
Welding is carried out by an electric arc that burns between a non-consumable electrode and the edges of the sides. Where a stronger weld is required, filler wire is added.
These types of welding made it possible to join stainless steel and aluminum, and the specialists quickly liked the cleanliness of the seam.
The latest achievements in the field of welding materials include:
To summarize, the history of welding development has several key points on the timeline. They can be distinguished as follows:
- 1802 - Russian scientist V.V. Petrov discovered the occurrence of an electrical discharge, characterized by a bright white light, the retention of which for a certain time leads to the rapid formation of temperature and ignition of the coal.
- 1803 - Petrov publishes his own publication, where he describes personal experiments in reproducing a voltaic column and an electric arc, as well as the use of these physical phenomena for electric welding and soldering of metal materials. At the same time, the scientist described the possibility of using an arc to create lighting.
- 1882 is a historical date when N.N. Benardos reproduced electric arc welding using carbon electrodes. The scientist received patents for his discovery in Russia, Germany, England, France, Italy and the USA. The method received the peculiar name “electrohephaestus”.
- 1888 - N.G. Slavyanov, being a pioneering practitioner, put into practice the use of a consumable electrode and an additional layer of flux on a metal surface. With observers from the state commission, he welded a part from a steam engine. Five years later, the scientist received a medal at a world exhibition in America for welding in a layer of crushed glass flux.
- 1905 - V.F. Mitkevich made a rational proposal to use a three-phase arc when connecting metal parts. This made it possible to work with thicker materials and create deep, strong seams with coated electrodes.
- 1932 - another Soviet scientist K.K. Khrenov implemented electric arc welding in an underwater environment. This gave rise to various deep methods of laying communications through bodies of water, and also improved repair work on ships.
- 1939 - E.O. Paton tested submerged arc welding methods and created heads for automatic machines. Later, the institute, named after this scientist, introduced many innovative ideas to improve various methods of welding metals.
Welding, the history of which will continue, has made it possible to create many structures and products, without which modern construction and other developments would be impossible. Scientists continue to work on creating more economical devices capable of joining metals of different structures. But the basic technological processes by which welding is carried out remain the same as 100 years ago.
Source: https://steelfactoryrus.com/kto-izobrel-svarochnyy-apparat/
Manual arc welding - video and operating principle of the welding machine for beginners
The RDS method is the most common and accessible method of welding with a coated electrode. The instructions for manual arc welding video clearly show that this method is mobile and easy to use, and does not require any additional equipment. To get acquainted with welding techniques and learn everything about the “manual arc welding” method, watch the video on our website.
The essence of the RDS process
The essence of manual arc welding is that the metal being welded is melted by the heat of the arc, and the ignition, maintenance and movement of the arc is carried out manually. One of the elements is a metal rod, and the other is the product to be welded.
With the help of a current source (alternating or direct), a welding arc is formed at the tip of the electrode, which melts the electrode itself and the product, forming a liquid weld pool, from which a future seam is then formed as it cools.
The seam is then covered with a slag crust, which is beaten off with a hammer after welding is completed. Sometimes welds require additional processing or cleaning.
After watching various video instructions for beginners, arc welding will become a clear process.
This method is suitable for welding carbon, low alloy, structural, high alloy, heat resistant steels. It can also be used to cut and weld metal. Using special electrodes, it is possible to weld non-ferrous metals.
As you can see in the video, electric arc welding of cast iron or stainless steel is carried out using direct current, and aluminum - using alternating current.
Types and methods of RDS
There are the following methods and types of manual arc welding: welding “with the coating supported” (gives a greater depth of penetration), “beam” welding (increases productivity), welding “tub” method (allows you to save energy and reduces costs, used for welding reinforcement bars) , welding with a “three-phase” arc (the stability of the arc is ensured), as well as welding with an “inclined” or “lying” electrode (serves to mechanize the process).
Welding machines, types and principle of operation
Information for beginners will be useful: arc welding can be carried out using completely different equipment: transformer sources, rectifiers, inverters.
Any welding machine is, first of all, a source of welding current, which is necessary to obtain and maintain a welding arc. The operating principle of the welding machine is as follows.
Its housing contains a power transformer that converts the current from the socket (AC) with high voltage into welding current (AC or DC) with a reduced safe voltage. With the help of a transformer, the current is also adjusted and the required current-voltage characteristic is formed.
The welding machine is connected to a socket (primary current), and depending on the voltage (220/380 V), a welding cable is connected to the secondary current in the connectors on the front panel of the machine using current tips. The type of source used will determine what welding current will be output from the machine. It can be variable or constant.
The operating principle of a DC welding machine is based on the conversion of alternating current from the network, but, thanks to the rectifier unit in the design of such devices, the current is rectified and becomes constant.
Next, an electrode holder and a grounding terminal (or a mass clamp on the product) are connected to the cable. When welding with direct current, the amount of heat on the electrodes is different, therefore the concept of polarity was introduced in welding. As shown in the video, electric arc welding can be performed with direct or reverse polarity.
The electrode holder can be connected to both the “positive” connector (reverse polarity) and the “negative” connector (straight polarity). Which polarity to choose when welding depends on the thickness of the product and the brand of electrodes used. The classic connection method is “plus” on the holder. The mass clamp is securely attached to the product or workpieces.
The method of attaching a mass clamp to a welding table is also quite common. The welding current is set before starting welding using a special regulator, and its value depends on the thickness of the metal that will have to be welded and on the selected electrode diameter. The power of the holder, grounding terminals, as well as the thickness of the welding cable are selected depending on the value of the welding current.
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Source: https://swarka-rezka.ru/ruchnaya-dugovaya-svarka-video-i-princip/
Inverter welding machine: what is it and how to choose it correctly?
Currently, inverter-type machines are often used for welding. Such equipment is distinguished by its low weight, high quality of work performed, and manufacturability.
Design of a welding inverter.
What is an inverter device?
Inverter welding machines were invented only in the twentieth century.
However, in a short time they became the most common types among welding equipment.
A welding inverter is a power transformer designed to reduce the network voltage to obtain the required no-load voltage. The operating principle of the equipment is as follows. The AC mains voltage is supplied to the rectifier, then to the power module, where DC is converted into alternating current at a higher frequency. Next, the current is supplied to a high-frequency welding transformer, the voltage from which goes to the welding arc.
Inverter welding machine is divided into several types:
- for manual arc welding MMA - used for working with metal using an electrode;
- for semi-automatic MIG/MAG welding - used for working with metal using filler wire fed into the work area using a feed mechanism;
- for argon-arc welding TIG - used for welding metals using a non-consumable tungsten electrode;
- for plasma cutting CUT - designed for cutting metals using an air-plasma jet.
The inverter welding machine is easy to use and simple to operate.
The inverter device has a number of advantages:
- reduction in the size of the power transformer and, as a consequence, reduction in size and weight;
- improving the dynamic and quality characteristics of the arc;
- increased efficiency;
- minimum number of sparks with a small spray radius;
- smooth parameter adjustments.
In addition, the inverter welding machine can be additionally equipped with various functions that improve the operation of the equipment and make it safer. Such functions include protection against overheating, against voltage surges, against increased danger of electric shock, arc force, hot start, built-in fan and much more.
Selecting a welding inverter
The principle of operation of the inverter.
It became clear what an inverter device is. Now let's look at how to choose it correctly, what should be taken into account when purchasing. When choosing an inverter welding machine, you should take into account its purpose and frequency of use.
If the device is required for periodic use, then simpler options should be considered. If the work will be carried out with enviable consistency, then you need to buy professional or semi-professional equipment.
Such devices have higher technical characteristics and often have a number of additional functions that make the work better and safer.
An important characteristic of an inverter device is the on-time - the percentage of continuous operation of the equipment relative to the total duration of use of the inverter. The higher the indicator, the less likely it is that the equipment will overheat when operating at high welding currents.
You should pay attention to the presence of such additional functions as arc force, anti-stick and hot start. They are necessary during work and greatly simplify the entire process. It is worth noting that these functions are available in almost all inverter models.
You should not take equipment less than 160 A. The difference in price is small, but the power and reliability are significantly improved. In addition, it is worth having a reserve of power for the future. If not so much power is currently required, then the work may become more difficult in the future. After all, the device, as a rule, is not purchased for one-time use.
You should pay attention to the manufacturing company. It is better to give preference to brands that have been known on the market for several years and have a proven track record. The warranty period and the availability of service stores should also be taken into account. It is much easier to carry out repairs if you can easily find original spare parts for the equipment.
And, of course, the cost of equipment. This parameter always plays an important role in the final choice. The price range is very wide. However, you should immediately take into account that a high-quality welding inverter will not be cheap. Therefore, it is better to buy a model that is more expensive, but which will not break after the first use.
Thus, inverters are currently the best choice for welding metals. They are in many ways superior to all other types of welding machines.
Source: https://moyakovka.ru/instrumenty/chto-takoe-invertornyi-svarochnyi-apparat.html
