Welding for dummies

Introduction About this book Conventions used in this book What you're not to read Foolish assumptions How this book is organized Part 1: Understanding Welding Basics Part 2: Welding On A Budget: Exploring Stick And Tig Welding Part 3: Discovering Mig Welding Part 4: Getting Fancy: Plasma Cutting, Oxyfuel Cutting, And Special Processes Part 5: Putting Welding Into Action With Projects And Repairs Part 6: Part Of Tens Icons used in this book Where to go from here Part 1: Understanding Welding Basics Chapter 1: Diving into the world of welding If you can't beat 'em, join 'em: understanding why welding matters Fabricating metal products Repairing metal pieces or products Getting familiar with metals Steel Stainless steel Aluminum Taking the time to understand welding safety Exploring welding methods Stick welding Mig welding Tig welding Other welding methods Looking at the future of welding Chapter 2: Considering commonly welded metals Steeling yourself for using steel Getting a handle on forms of steel Knowing when steel is appropriate Preparing steel for welding Exploring steel welding methods Going with stainless steel Understanding the differences between steel and stainless steel Deciding when to use stainless steel Looking at stainless steel welding methods Working with aluminum Perusing the properties of aluminum Eyeing aluminum welding techniques Considering other metals Chapter 3: Setting your sights on welding safety Gearing up to protect yourself Choosing eye protection Keeping the right fire extinguisher on hand Wearing protective clothing Watching health hazards: using a respirator and material safety data sheets Observing basic safety rules Keeping your work space clean Checking for leaks Getting the ventilation right Storing flammable liquids and gases Knowing your surroundings Protecting yourself from electric shock Shielding yourself from burns Maintaining your equipment Being prepared for injuries and accidents Equipping your first-aid kit Knowing how to handle injuries Chapter 4: Setting up your welding shop Choosing a location Deciding how much space you need Contemplating indoor versus outdoor Equipping your welding shop Making sure you have the basic hand tools Choosing a welding table Selecting your welding machine Considering a few accessories for your welding shop

Part 2: Welding On A Budget: Stick And Tig Welding Chapter 5: Getting on the stick: understanding stick welding Looking at the pros and cons of stick welding Understanding the factors that influence stick welding Getting familiar with stick welding equipment Discovering the differences among stick welding machines Setting up your stick welding machine Nailing down the basics of stick welding's electrodes Choosing tools and supplies every stick welder needs Chapter 6: Getting to work with stick welding Preparing to stick weld Setting up your work area Understanding stick welding electrodes Setting the machine Choosing polarity Setting the amperage Preparing to weld Striking and maintaining an arc Assume the position: stick welding in all positions Welding on a flat surface Going vertical Exploring horizontal welding Reaching overhead Chapter 7: To tig or not to tig: understanding tig welding Taking a closer look at tig welding components Considering the advantages and disadvantages of tig welding Brushing up on tig welding basics Showing your metal: looking at a few metals for tig welding Taking steps to ensure quality welds Stocking the shop: examining tig welding equipment Considering fully equipped tig machines Thinking about tig torches Selecting and managing shielding gas Controlling current and amperage Selecting filler metal Exploring tungsten electrodes Chapter 8: Trying out tig welding Getting your welding setup tig-ether Taking care of tungsten electrode details Making sure your shielding gas is set up correctly Figuring out your tig filler rods Matching materials and settings Getting a handle on using your tig torch Choosing an electrical current and striking the arc Get a grip: holding your tig torch correctly Giving tig welding a try Tackling the first weld Trying a butt joint Welding a lap joint Making a T joint Part 3: Discovering Mig Welding Chapter 9: Understanding the ABCs of mig welding Understanding how mig welding works Considering mig welding's advantages and limitations Bringing out the big guns (and other mig welding equipment) Mig welding machines Mig welding guns Electrode wire feeders Sifting through shielding gases for mig welding Taking a look at electrode wire Adjusting mig equipment to suit your mig welding project

Chapter 10: Practicing mig welding Preparing to mig weld Getting the equipment ready Setting the wire feed speed and voltage Trying out mig welding Making vertical mig welds Joining pieces of sheet metal Watching out for common mig welding defects Part 4: Getting Fancy: Plasma Cutting, Oxyfuel Cutting, And Other Processes Chapter 11: Examining plasma and oxyfuel cutting Understanding plasma arc cutting Identifying some good materials for plasma cutting Taking a look at plasma cutting's advantages and disadvantages Perusing and preparing plasma arc cutting equipment Getting a handle on plasma cutting equipment Setting the equipment up properly Exploring oxyfuel cutting basics Considering what you can (and can't) cut with oxyfuel Looking at the pros and cons of oxyfuel cutting Checking out and setting up oxyfuel cutting equipment Examining oxyfuel cutting equipment Deciding among different gas cylinder sizes Setting up oxyfuel cutting equipment Chapter 12: Ready, set, cut! Trying out plasma arc cutting and oxyfuel cutting Exploring plasma arc cutting Slicing a straight line Cutting a circle Creating a bevel Practicing oxyfuel cutting Lighting the torch Making a straight cut Cutting out a circle Taking on a beveled edge Chapter 13: Exploring special weld processes Working through the basics of welding with gas Taking a gander at gas cylinders Looking at more gas welding equipment Getting to work with gas welding Discovering brazing (braze welding) Keeping a few brazing rules in mind Giving brazing a try Finding out about fusion welding Soldering on: exploring soldering Following the rules of soldering Understanding the two types of soldering Trying the soldering process Chapter 14: Exploring pipe welding Delving into the different kinds of pipe Getting down to welding steel pipes Getting set up and preparing the pipe Making the tacks Welding the pipes Trying some other angles Peeking at a few more types of pipe welding joints Keeping an eye out for common pipe welding defects Chapter 15: Working with cast iron Casting light on the three most common types of cast iron Gray cast iron Malleable cast iron Nodular cast iron Getting the (cast) iron in the fire: welding gray cast iron Stick welding cast iron Oxyfuel welding cast iron Mig welding cast iron Part 5: Putting Welding Into Action With Projects And Repairs Chapter 16: Two welding projects to boost your welding shop Creating a torch cart Gathering the materials Acquiring the right steel pieces Measuring and cutting pieces Making the welds Adding the wheels Checking your welds Picking out your paint Fabricating your own portable welding table Rounding up your tools Picking out the parts Assembling the pieces Ensuring smooth edges Choosing your paint Putting on the wheels Chapter 17: Constructing a campfire grill Fabricating a campfire grill Getting your tools in order Obtaining the proper steel pieces Cutting the steel pieces to length Welding the grill Picking out your paint Seasoning the cooking surface

Chapter 18: Fixin' to fix things: analyzing and planning

Determining whether something is fixable

Planning a repair strategy

Identifying the metal and what it means for the repair

Deciding which welding process to use for your repair

Making and following your plan

Getting ready to make repair welds

Preparing your repair piece and work area

Gathering your equipment and tools

Selecting filler rods and electrodes

Considering cracks

Part 6: Part Of Tens

Chapter 19: Ten tools every welder wants

4 1/2 inch grinder

Hacksaw

Air compressor

3/8-inch electric drill

Wrench set

Steel sawhorses

Cutoff saw

Bench grinder

Bottle jack

Toolbox

Chapter 20: (Not quite) ten advantages of being a certified welder

More job opportunities

Better pay

More chances for advancement

Certification that travels with you

Ability to join a national organization

Qualification in specific areas of welding

Increased confidence in your welding skills

Listing in the American Welding Society database

Head start on additional types of welding certification

Chapter 21: (Almost) ten welding defects

Incomplete penetration

Incomplete fusion

Undercutting

Slag inclusions

Flux inclusions

Porosity

Cracks

Warpage

Spatter

Chapter 22: Ten signs you're welding correctly

Weld is distributed equally between parts

Slag or shielding material doesn't stick to the weld

No holes or irregularities on the weld surface

Weld is tight

Weld is leakproof

Weld has full penetration

Weld has no undercutting

Weld has no overlap

Weld meets strength requirements

You're safe and healthy

Chapter 23: Ten maintenance tips for your welding equipment and shop

Checking on your hand tools

Taking care of power tools

Doing basic housekeeping in the shop

Protecting your welding helmet

Seeking to stick welding machine maintenance

Working on maintaining your mig welding machine

Tuning up your tig welding machine

Taking care of your oxyfuel equipment

Keeping your air compressor working

Drill press maintenance

Glossary

Index.