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Every critical welding technique and process distilled into a one-stop, accessible resource
Safe and effective welding might seem like a pipe dream if you’re just getting started. But with a little help from Welding For Dummies you’ll be a “golden arm” in no time. This guide will give you techniques you need to get a handle on material evaluation, clean-up, and every step in between.
You’ll find practical advice on every popular kind of welding, including stick, tig, mig, fluxcore, and even oxyfuel cutting. You’ll also get tips on the ideal welding techniques to choose for specific projects. The book shows you how to:
Whether you’re looking for some help to further your do-it-yourself projects at home or you’re just getting started with a traditional welding educational program and you need a useful supplementary resource, Welding For Dummies is an irreplaceable reference that helps make a challenging trade accessible to everyone.
Steven Robert Farnsworth, is a certified welding inspector and instructor with over 20 years of experience teaching all methods of welding. He previously served as a welder in the United States Navy.
Introduction 1
About This Book 1
Conventions Used in This Book 2
What You’re Not to Read 2
Foolish Assumptions 3
How This Book Is Organized 3
Part 1: Understanding Welding Basics 3
Part 2: Welding on a Budget: Stick and Tig Welding 4
Part 3: Discovering Mig Welding 4
Part 4: Getting Fancy: Plasma Cutting, Oxyfuel Cutting, and Other Processes 4
Part 5: Putting Welding into Action with Projects and Repairs 4
Part 6: The Part of Tens 5
Icons Used in This Book 5
Where to Go from Here 5
Part 1: Understanding Welding Basics 7
Chapter 1: Diving Into the World of Welding 9
If You Can’t Beat ’Em, Join ’Em: Understanding Why Welding Matters 10
Fabricating metal products 10
Repairing metal pieces or products 11
Getting Familiar with Metals 12
Steel 13
Stainless steel 13
Aluminum 14
Taking the Time to Understand Welding Safety 14
Exploring Welding Methods 15
Stick welding 15
Mig welding 16
Tig welding 17
Other welding methods 18
Looking at the Future of Welding 18
Chapter 2: Considering Commonly Welded Metals 19
Steeling Yourself for Using Steel 20
Getting a handle on forms of steel 20
Knowing when steel is appropriate 21
Preparing steel for welding 23
Exploring steel welding methods 26
Going with Stainless Steel 27
Understanding the differences between steel and stainless steel 27
Deciding when to use stainless steel 27
Looking at stainless steel welding methods 28
Working with Aluminum 29
Perusing the properties of aluminum 29
Eyeing aluminum welding techniques 30
Considering Other Metals 30
Chapter 3: Setting Your Sights on Welding Safety 33
Gearing Up to Protect Yourself 34
Choosing eye protection 34
Keeping the right fire extinguisher on hand 36
Wearing protective clothing 38
Watching health hazards: Using a respirator and Material Safety Data Sheets 39
Observing Basic Safety Rules 40
Keeping your work space clean 41
Checking for leaks 42
Getting the ventilation right 42
Storing flammable liquids and gases 43
Knowing your surroundings 44
Protecting yourself from electric shock 45
Shielding yourself from burns 46
Maintaining your equipment 47
Being Prepared for Injuries and Accidents 48
Equipping your first-aid kit 48
Knowing how to handle injuries 49
Chapter 4: Setting Up Your Welding Shop 53
Choosing a Location 54
Deciding how much space you need 54
Contemplating indoor versus outdoor 55
Equipping Your Welding Shop 56
Making sure you have the basic hand tools 58
Choosing a welding table 60
Selecting your welding machine 61
Considering a few accessories for your welding shop 67
Part 2: Welding on a Budget: Stick and Tig Welding 71
Chapter 5: Getting on the Stick: Understanding Stick Welding 73
Looking at the Pros and Cons of Stick Welding 74
Understanding the Factors That Influence Stick Welding 75
Getting Familiar with Stick Welding Equipment 76
Discovering the differences among stick welding machines 76
Setting up your stick welding machine 80
Nailing down the basics of stick welding’s electrodes 80
Choosing tools and supplies every stick welder needs 81
Chapter 6: Getting to Work with Stick Welding 85
Preparing to Stick Weld 86
Setting up your work area 86
Understanding stick welding electrodes 87
Setting the Machine 90
Choosing polarity 91
Setting the amperage 91
Preparing to weld 92
Striking and Maintaining an Arc 93
Assume the Position: Stick Welding in All Positions 95
Welding on a flat surface 96
Going vertical 97
Exploring horizontal welding 101
Reaching overhead 102
Chapter 7: To Tig or Not To Tig: Understanding Tig Welding 105
Taking a Closer Look at Tig Welding Components 106
Considering the Advantages and Disadvantages of Tig Welding 107
Brushing Up on Tig Welding Basics 108
Showing your metal: Looking at a few metals for tig welding 108
Taking steps to ensure quality welds 109
Stocking the Shop: Examining Tig Welding Equipment 110
Considering fully equipped tig machines 112
Thinking about tig torches 113
Selecting and managing shielding gas 113
Controlling current and amperage 116
Selecting filler metal 117
Exploring tungsten electrodes 118
Chapter 8: Trying Out Tig Welding 119
Getting Your Welding Setup Tig-ether 119
Taking care of tungsten electrode details 120
Making sure your shielding gas is set up correctly 122
Figuring out your tig filler rods 122
Matching Materials and Settings 123
Getting a Handle on Using Your Tig Torch 125
Choosing an electrical current and striking the arc 125
Get a grip: Holding your tig torch correctly 127
Giving Tig Welding a Try 127
Tackling the first weld 128
Trying a butt joint 129
Welding a lap joint 130
Making a T joint 131
Part 3: Discovering Mig Welding 133
Chapter 9: Understanding the ABCs of Mig Welding 135
Understanding How Mig Welding Works 136
Considering Mig Welding’s Advantages and Limitations 138
Bringing Out the Big Guns (And Other Mig Welding Equipment) 140
Mig welding machines 140
Mig welding guns 141
Electrode wire feeders 141
Sifting Through Shielding Gases for Mig Welding 142
Taking a Look at Electrode Wire 144
Adjusting Mig Equipment to Suit Your Mig Welding Project 147
Chapter 10: Practicing Mig Welding 149
Preparing to Mig Weld 149
Getting the equipment ready 150
Setting the wire feed speed and voltage 152
Settings for flux-cored arc welding 153
Settings for aluminum MIG welding 154
Trying Out Mig Welding 155
Making vertical mig welds 158
Joining pieces of sheet metal 159
Watching Out for Common Mig Welding Defects 160
Part 4: Getting Fancy: Plasma Cutting, Oxyfuel Cutting, and Other Processes 161
Chapter 11: Examining Plasma and Oxyfuel Cutting 163
Understanding Plasma Arc Cutting 163
Identifying some good materials for plasma cutting 164
Taking a look at plasma cutting’s advantages and disadvantages 165
Perusing and Preparing Plasma Arc Cutting Equipment 166
Getting a handle on plasma cutting equipment 166
Setting the equipment up properly 168
Exploring Oxyfuel Cutting Basics 169
Considering what you can (and can’t) cut with oxyfuel 169
Looking at the pros and cons of oxyfuel cutting 170
Checking Out and Setting Up Oxyfuel Cutting Equipment 170
Examining oxyfuel cutting equipment 171
Deciding among different gas cylinder sizes 174
Setting up oxyfuel cutting equipment 174
Chapter 12: Ready, Set, Cut! Trying Out Plasma Arc Cutting and Oxyfuel Cutting 177
Exploring Plasma Arc Cutting 178
Slicing a straight line 179
Cutting a circle 180
Creating a bevel 181
Practicing Oxyfuel Cutting 182
Lighting the torch 183
Making a straight cut 185
Cutting out a circle 186
Taking on a beveled edge 187
Chapter 13: Exploring Special Weld Processes 189
Working Through the Basics of Welding with Gas 189
Taking a gander at gas cylinders 190
Looking at more gas welding equipment 191
Getting to work with gas welding 193
Discovering Brazing (Braze Welding) 197
Keeping a few brazing rules in mind 197
Giving brazing a try 198
Finding Out about Fusion Welding 200
Soldering On: Exploring Soldering 201
Following the rules of soldering 202
Understanding the two types of soldering 204
Trying the soldering process 204
Chapter 14: Exploring Pipe Welding 207
Delving into the Different Kinds of Pipe 208
Getting Down to Welding Steel Pipes 208
Getting set up and preparing the pipe 209
Making the tacks 211
Welding the pipes 213
Trying some other angles 214
Peeking at a Few More Types of Pipe Welding Joints 216
Keeping an Eye Out for Common Pipe Welding Defects 217
Chapter 15: Working with Cast Iron 219
Casting Light on the Three Most Common Types of Cast Iron 219
Gray cast iron 220
Malleable cast iron 220
Nodular cast iron 221
Getting the (Cast) Iron in the Fire: Welding Gray Cast Iron 223
Stick welding cast iron 223
Oxyfuel welding cast iron 226
Mig welding cast iron 228
Part 5: Putting Welding into Action with Projects and Repairs 231
Chapter 16: Two Welding Projects to Boost Your Welding Shop 233
Creating a Torch Cart 233
Gathering the materials 235
Acquiring the right steel pieces 235
Measuring and cutting pieces 237
Making the welds 238
Adding the wheels 242
Checking your welds 243
Picking out your paint 244
Fabricating Your Own Portable Welding Table 244
Rounding up your tools 245
Picking out the parts 246
Assembling the pieces 246
Ensuring smooth edges 249
Choosing your paint 250
Putting on the wheels 250
Chapter 17: Constructing a Campfire Grill 251
Fabricating a Campfire Grill 251
Getting your tools in order 252
Obtaining the proper steel pieces 253
Cutting the steel pieces to length 255
Welding the grill 256
Picking out your paint 258
Seasoning the cooking surface 259
Chapter 18: Fixin’ to Fix Things: Analyzing and Planning 261
Determining Whether Something Is Fixable 262
Planning a Repair Strategy 263
Identifying the metal and what it means for the repair 264
Deciding which welding process to use for your repair 267
Making and following your plan 268
Getting Ready to Make Repair Welds 269
Preparing your repair piece and work area 270
Gathering your equipment and tools 271
Selecting filler rods and electrodes 271
Considering Cracks 273
Part 6: The Part of Tens 275
Chapter 19: Ten Tools Every Welder Wants 277
4½-Inch Grinder 278
Hacksaw 278
Air Compressor 278
⅜-Inch Electric Drill 279
Wrench Set 280
Steel Sawhorses 281
Cutoff Saw 281
Bench Grinder 283
Bottle Jack 284
Toolbox 284
Chapter 20: (Not Quite) Ten Advantages of Being a Certified Welder 287
More Job Opportunities 288
Better Pay 289
More Chances for Advancement 289
Certification that Travels with You 290
Ability to Join a National Organization 290
Qualification in Specific Areas of Welding 291
Increased Confidence in Your Welding Skills 291
Listing in the American Welding Society Database 292
A Head Start on Additional Types of Welding Certification 292
Chapter 21: (Almost) Ten Welding Defects 293
Incomplete Penetration 294
Incomplete Fusion 295
Undercutting 296
Slag Inclusions 296
Flux Inclusions 297
Porosity 298
Cracks 299
Warpage 300
Spatter 301
Chapter 22: Ten Signs You’re Welding Correctly 303
The Weld Is Distributed Equally between Parts 304
The Slag or Shielding Material Doesn’t Stick to the Weld 304
No Holes or Irregularities on the Weld Surface 305
The Weld Is Tight 305
The Weld Is Leakproof 305
The Weld Has Full Penetration 306
The Weld Has No Undercutting 306
The Weld Has No Overlap 307
The Weld Meets Strength Requirements 307
You’re Safe and Healthy 308
Chapter 23: Ten Maintenance Tips for Your Welding Equipment and Shop 309
Checking on Your Hand Tools 309
Taking Care of Power Tools 311
Doing Basic Housekeeping in the Shop 312
Protecting Your Welding Helmet 312
Seeing to Stick Welding Machine Maintenance 313
Working on Maintaining Your Mig Welding Machine 314
Tuning Up Your Tig Welding Machine 316
Taking Care of Your Oxyfuel Equipment 317
Keeping Your Air Compressor Working 318
Drill Press Maintenance 318
Glossary 321
Index 341
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