[PDF] Welding Guide - LEARNING TO WELD

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Refer to

http://www.lincolnelectric.com/safety for additional safety information.Welding SafetyInteractive Web Guidefor mobile devices

Safety DepenDS on yogu

The serviceability of a product or structure utiliz1ing this type of information is and must be the sole responsibility 1of the builder/user. Many variables beyond the control of The Lincoln 1Electric Company affect the results obtained in applying this type 1of information. These variables include, but are not limited to, weldin1g procedure, plate chemistry and temperature, weldment design, fabrication1 methods and service requirements. This statement appears where the information must b1e followed exactly to avoid serious personal injury or loss 1of life. This statement appears where the information must b1e followed to avoid minor personal injury or damage to this eq1uipment.

Keep youR heaD out gof the fumeS.

1FEsNget too close to the arc. Use

corrective lenses if necessary to stay a reasonable distance away from the arc.

L2-1and obey the Material Safety

Data Sheet (MSDS) and the warning

label that appears on all containers of welding materials.

OM22EFO56P2EN9C-N9FCEor

exhaust at the arc, or both, to keep the fumes and gases from your breathing zone and1 the general area.

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, natural ventilation may be adequate if you keep your head out of the fum1es (See below). OM2E-NOL-C1L-4NMor fans to keep the fumes away from your face. If you de velop unusual symptoms, see your supervisor. Perhaps1 the welding atmosphere and ventilation system should be 1checked. weaR coRRect eye, egaR & boDy pRotectiong

GLFN20Nyour eyes and face with welding helmet

properly fitted and with proper grade of filter 1plate (See ANSI Z49.1).

GLFN20Nyour body from welding spatter and arc

flash with protective clothing including woolen clothing, flame-proof apron and gloves, leather leggings, and high boots. GLFN20Nothers from splatter, flash, and glare with protective screens or barriers.

9EMFD2-L2-M

, protection from noise may be appropriate. .2MOL2protective equipment is in good condition.

SpeciaL SituationS

1FEFNR2C1FL0ONcontainers or materials which previously had

been in contact with hazardous substances unless th1ey are properly cleaned. This is extremely dangerous.

1FEFNR2C1FL0ONpainted or plated parts unless special

precautions with ventilation have been taken. They 1can release highly toxic fumes or gases.

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GLFN20Ncompressed gas cylinders from excessive heat, mechani1cal shocks, and arcs; fasten cylinders so they cann1ot fall. .2MOL2cylinders are never grounded or part of an elect1rical circuit.

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all potential fire hazards from welding area.

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TABLEOFCONTENTS

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SELF-SHIELDED FCAW

(FLUX-CORED ARC WELDING) Figure 3 illustrates the action taking place 1in the self-shielded FCAW (Innershield) welding arc. It closely resembles 1what is actually seen while welding.

FIGURE 3

The "arc stream" is seen in the middle of the1 picture. This is the electric arc created by the electric current flowin1g through the space between the end of the wire electrode and the 1base metal. The temperature of this arc is about 6000°F, 1which is more than enough to melt metal. The arc is very bright, as well as hot, and0 cannot be looked at with the naked eye without risking painful in0jury. A very dark lens, specifically designed for arc welding, 0must be used with a welding helmet whenever viewing the 0arc. /120 3,.()"-- The arc melts the base metal and actually digs 1into it much as water through a nozzle on a garden hose digs into t1he earth. The molten metal forms a molten pool or crater and tends 1to flow away from the arc. As it moves away from the arc, it c1ools and solidifies. The function of the Innershield cored wire electrod1e is much more than simply to carry current to the arc. The 1wire core is composed of fluxes and/or alloying ingredients around which a 1steel sheath has been formed. It is simply a stick electrode tur1ned inside out in a continuous wire form. The cored wire melts in the arc and tiny drop1lets of molten metal shoot across the arc into the molten pool. The 1wire sheath provides additional filler metal for the joint to fill th1e groove or gap between the two pieces of base metal. The core materials also melt or burn in the a1rc and perform several functions. They make the arc steadier, provide a 1shield of smoke-like gas around the arc to keep oxygen and nitrogen 1in the air away from the molten metal, and provide a flux for the 1molten pool. The flux picks up impurities and forms the protective slag 1on top of the weld during cooling. After running a weld bead, the slag may be 1removed with a chipping hammer and wire brush. This improves appearance an1d allows for inspection of the finished weld. Since machine size and output characteristics limit 1the size and type of wire electrode which can be used, check your1 Instruction Manual "Application Chart" or see the Application 1Guide on the inside door of the Machine. This will give you the proper elec1trode size and control settings to be used. GMAW (GAS METAL ARC WELDING) Figure 4 illustrates the GMAW (Also 1referred to as MIG) welding arc. Solid wire does not contain fluxes or ingredients 1to form its own shielding, and no slag forms to protect the mol1ten weld metal. For this reason, a continuous, even flow of shielding gas 1is needed to protect the molten weld metal from atmospheric contaminants 1such as oxygen and nitrogen. Shielding gas is supplied thr1ough the gun and cable assembly, through the gas nozzle, and into 1the welding zone.

Important!

The MIG welding process requires that the welder1 has a gas solenoid valve installed in order to control the flow of 1the shielding gas. Read your Operators Manual to see if your machine req1uires additional items to MIG weld. When comparing the GMAW and FCAW proces1ses, you can see that the principal difference between the two lies in 1the type of shielding used. GMAW uses gas for shielding, thus we 1have Gas Metal Arc Welding. FCAW uses the melting or burning 1of the core ingredients for shielding, and is thus termed Self-Shielded Flux-1Cored Arc Welding. The recommended LINCOLN Super Arc L-56 so1lid wire and gas for Gas Metal Arc Welding (MIG) Metal Inert1 Gas is also located in the Instruction Manual "Application Chart"; you 1may also see the Application Guide on the inside door of the 1machine. This machine is capable of welding a wide range of mild steels 1in all positions, however, more skill IS required for out-of-position1 welding with the

GMAW process.

weRoLoK jLKuRi a

Gas nozzle

Shielding gas

Solid wire

electrode

Contact Tip

Base metal

Weld metal

Burning of core materials

inside the wire electrode provides a gas to shield the molten metal as it solidifies.

Arc Stream

Weld Puddle

Cored Wire

Protective Slag

Weld Metal

DRAG TECHNIQUE

PUSH TECHNIQUE

DIRECTION OF TRAVEL

DIRECTION OF TRAVEL

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PROCESS SELECTION

By gaining knowledge of the differences between 1the two processes, you will be able to select the best process f1or the job you have at hand. In selecting a process, you should ask y1ourself the following questions:

For GMAW (MIG) Process

1. Is most of my welding performed on 16 gaug0e and

lighter materials?

2. Can I afford the extra expense, space, and 0lack of

portability required for gas cylinders and gas supp0ly?

3. Do I require clean, finished-looking welds?

4. Must the base metal be clean?

If you have answered yes to all the above que1stions, GMAW may be the process for you. If you have answered no 1to any of the above questions, then you should consider using the F1CAW process.

For FCAW (Innershield) Process

1. Do I want simplicity and portability?

2. Will welding be performed outdoors or under windy

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