Learn How to Weld

Questions, answers, tips & tricks for newbies and veterans alike

Learn How to Weld

Postby Toolmaker » Sat Mar 17, 2007 12:08 am

The following is enough knowledge to get ANYONE started. The rest comes with practice and experience. If you read everything below you will know almost everything thats essential. Remember.. always wear protection and have ventilation!

Safety
http://www.millerwelds.com/pdf/safety/m199776c.pdf

Welding Dictionary
http://www.millerwelds.com/education/dictionary.html

SMAW (Stick)
http://www.millerwelds.com/pdf/guidelines_smaw.pdf
http://www.millerwelds.com/education/te ... tick_tips/
http://www.millerwelds.com/education/ca ... ulator.php

GMAW (MIG)
http://www.millerwelds.com/pdf/mig_handbook.pdf
http://www.millerwelds.com/education/te ... /MIG_tips/
http://www.millerwelds.com/education/ca ... ulator.php
http://www.millerwelds.com/education/ca ... ulator.php

GTAW
http://www.millerwelds.com/pdf/gtawbook.pdf

Submerged Arc
http://www.millerwelds.com/pdf/Submerged.pdf

Resistance Spot
http://www.millerwelds.com/pdf/Resistance.pdf

Arc Stud
http://www.millerwelds.com/pdf/ArcStudWelding.pdf

Welding History
http://www.millerwelds.com/pdf/WorldofMetals.pdf

Fundamentals of Electricity applied to Arc welding
http://www.millerwelds.com/pdf/Basic.pdf

FREE online training course for Electricity
http://www.millerwelds.com/education/basicelec/

FREE online training course for MIG/GMAW
http://www.millerwelds.com/education/basicMIG/

Arc welding fundamentals
http://lincolnelectric.com/knowledge/ar ... ldfund.asp

Stick
http://lincolnelectric.com/knowledge/ar ... ckweld.asp

Troubleshoot GMAW problems
http://lincolnelectric.com/knowledge/ar ... t/gmaw.asp

Welding Aluminum
http://lincolnelectric.com/knowledge/ar ... t/alum.asp

Striking that perfect arc
http://lincolnelectric.com/knowledge/ar ... ikearc.asp

Taking care of your equipment so it lasts
http://lincolnelectric.com/knowledge/ar ... doctor.asp

MIG STAINLESS!!!
http://lincolnelectric.com/knowledge/ar ... weldss.asp

Plasma Cutting
http://lincolnelectric.com/knowledge/ar ... plasma.asp

TIG Aluminum
http://lincolnelectric.com/knowledge/ar ... igalum.asp
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Postby mdmf007 » Sat Mar 17, 2007 1:14 pm

That took some work to put together - great resources
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Postby Token » Sat Mar 17, 2007 10:06 pm

Toolmaker has ascended to Eplaya divinity!
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Postby Toolmaker » Sun Mar 18, 2007 4:27 am

More website based tutorials and whatnot. This website has lots of color pics and movies!

Welding Safety
http://www.mig-welding.co.uk/welding-safety.htm

Installing wire in MIG welder
http://www.mig-welding.co.uk/wire-feed.htm

Power and wire feed calculator
http://www.mig-welding.co.uk/calculator.htm

Positioning of gun and laying of welds
http://www.mig-welding.co.uk/learning-mig.htm

Setting wire feed speed
http://www.mig-welding.co.uk/wire-speed.htm

Adjusting power setting
http://www.mig-welding.co.uk/power-settings.htm

Joining two pieces / Butt welding
http://www.mig-welding.co.uk/butt-weld.htm

Welding thin sheetmetal
http://www.mig-welding.co.uk/thin-metal.htm

Working with flux core / Gasless MIG welding
http://www.mig-welding.co.uk/gasless-mig.htm

Filling holes / Plug welding / good alternative to spot welding
http://www.mig-welding.co.uk/plug-weld.htm

Other tips
http://www.mig-welding.co.uk/welding-tips.htm

Welding aluminum with MIG / Setup
http://www.mig-welding.co.uk/aluminium-setup.htm

Welding aluminum with MIG / Doing It
http://www.mig-welding.co.uk/aluminium-welding.htm

MIG brazing
http://www.mig-welding.co.uk/brazing.htm

Cast Iron brazing with your MIG
http://www.mig-welding.co.uk/cast-iron.htm

Things to consider about specifications when shopping for your Welder
http://www.mig-welding.co.uk/buying.htm

Shielding gas comparison
http://www.mig-welding.co.uk/welding-gas.htm
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Postby Toolmaker » Sun Mar 18, 2007 4:32 am

Want to build your own 70Amp Welder? This is not for the novice but great for ther hardcore survivalist and radically self reliant welder to know.

http://www.geocities.com/aaawelder/
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Postby Toolmaker » Sun Mar 18, 2007 5:03 am

Another really nice free learning tutorial that covers the basics. On right side of page there are buttons to "turn" pages. There WILL be a test to take afterwards if you so choose.

Lesson 1 Basics of Arc welding
http://www.esabna.com/EUWeb/AWTC/Lesson1_1.htm

Lesson 2 Common Electric Arc Welding Processes
http://www.esabna.com/EUWeb/AWTC/Lesson2_1.htm

Lesson 3 Covered Electrodes for Welding Mild Steels
http://www.esabna.com/EUWeb/AWTC/Lesson3_1.htm

Lesson 4 Covered Electrodes for Welding Low Alloy Steels
http://www.esabna.com/EUWeb/AWTC/Lesson4_1.htm

Lesson 5 Welding Filler Metals for Stainless Steels
http://www.esabna.com/EUWeb/AWTC/Lesson5_1.htm

Lesson 6 Carbon & Low Alloy Steel Filler Metals -GMAW,GTAW,SAW
http://www.esabna.com/EUWeb/AWTC/Lesson6_1.htm

Lesson 7 Flux Cored Arc Electrodes Carbon Low Alloy Steels
http://www.esabna.com/EUWeb/AWTC/Lesson7_1.htm

Lesson 8 Hardsurfacing Electrodes
http://www.esabna.com/EUWeb/AWTC/Lesson8_1.htm

Lesson 9 Estimating & Comparing Weld Metal Costs
http://www.esabna.com/EUWeb/AWTC/Lesson9_1.htm

Lesson 10 Reliability of Welding Filler Metals
http://www.esabna.com/EUWeb/AWTC/Lesson10_1.htm

Filler metal handbook / Choose the right filler to suit your needs!
http://www.esabna.com/EUWeb/FM_handbook/577fm1_1.htm

MIG welding handbook
http://www.esabna.com/EUWeb/MIG_handbook/592mig1_1.htm

Oxygen-Acetylene cutting handbook
http://www.esabna.com/EUWeb/OXY_handbook/589oxy1_1.htm

Submerged Arc welding handbook
http://www.esabna.com/EUWeb/SA_handbook/585sa1_1.htm

Knowledge Center / More cutting, filler metals, inspection and equipment
http://www.esabna.com/us/en/education/k ... /index.cfm


much more to come.. stay tuned eplayans
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Re: Learn How to Weld

Postby Rocket75377 » Sun Mar 18, 2007 7:01 am

Toolmaker wrote:Remember.. always wear protection and have ventilation!


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Postby Lassen Forge » Sun Mar 18, 2007 5:49 pm

Toolmaker...

You shall be mentioned in the tomes of history, alongside Michaelangelo and Cicero... That's not just wonderful, it is a blessing!!!

Humbly, I remain...
prostrate or something like that...
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Postby Cabana Springs » Sun Mar 18, 2007 6:55 pm

Much to my wife's chagrin, I spent the entire day reading all these welding links and watching the NCAA tournament. Nevada sucks. haha -

Thanks for the assist. I am ready to go forward and Weld.
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Postby MikeVDS » Sun Mar 18, 2007 8:40 pm

Ask him about sheet metal. I'm still going through the links he PMed me. :) Great sites as well. I'm sure he can fill you with knowledge of other manufacturing techniques as well if you dare to ask. The only problem is finding the time to finish reading them. :)
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Postby Toolmaker » Mon Mar 19, 2007 12:46 am

The following website has ALL kinds of knowledge, here is the list of free education categories

http://64.78.42.182/free-ed/FreeEdIDX.asp

They have welding here
http://64.78.42.182/free-ed/BldgConst/W ... g01_v2.asp

Knowledge base with tons of articles
http://lincolnelectric.com/knowledge/articles/list.asp

Historical reference for welding and brazing
http://weldinghistory.org/

The brazing book online
http://www.handyharmancanada.com/TheBra ... /bbook.htm

Design of machine elements (has link to chart of fillet weld sizes)
http://www.ecs.umass.edu/mie/labs/mda/d ... chine.html
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Postby Toolmaker » Mon Mar 19, 2007 1:16 am

Another knowledge base with structural fabrication, welding, etc
http://www.jflf.org/papers/default.asp

FSW / Friction stir welding AKA how a machinist can weld without a welder
http://www.alu-info.dk/Html/alulib/modul/A00635.htm

Index of other stuff at above website
http://www.alu-info.dk/Html/alulib/modul/Aindex.htm

More FSW
http://www.twi.co.uk/j32k/unprotected/b ... intro.html

Even more FSW with color pics and movies
http://www.msm.cam.ac.uk/phase-trans/2003/FSW/aaa.html

Main page for welding metallurgy
http://www.msm.cam.ac.uk/phase-trans/20 ... ing.1.html

Prevent weld failures (main page has a ton of stuff)
http://www.gowelding.com/weld/failure/failure.htm

MITs FREE Opencourseware (not welding but WTF since I'm on a roll I might as well include architecure and engineering stuff thats free)
http://ocw.mit.edu/index.html

Manufacturing process basics
http://www.efunda.com/processes/process ... rocess.cfm

I guess the wiki should be included
http://en.wikipedia.org/wiki/Welding
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Postby Archantael » Mon Mar 19, 2007 7:04 am

The Brazing Book link has been very helpful. The only problem is my g/f was looking over my shoulder as I read through it and she has some projects of her own that she wants to try....which means i'll have to share equipment. This could be quite fun. Thanks Toolmaker.
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Postby Cabana Springs » Mon Mar 19, 2007 10:06 am

Archantael wrote:The Brazing Book link has been very helpful. The only problem is my g/f was looking over my shoulder as I read through it and she has some projects of her own that she wants to try....which means i'll have to share equipment. This could be quite fun. Thanks Toolmaker.


There's many worse things than having to share your equipment with your girlfriend!
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Postby Toolmaker » Mon Mar 19, 2007 11:13 am

I'm glad everyone found the learning resources helpful. I have about 500 or so more that I will refrain from posting since alot of them are heavy into commerce ads. I tried to post the best sources I have that are commerce free. As Mike mentioned I also have alot of resources for fabrication and other manufacturing methods.. I am after all a Toolmaker and have to keep up with this stuff. A few of those links have other wonderful things covered, just take out the end of the link and go right to the .com and see what else you have. The MIT website is a really nice one I found recently that covers a nice wide range of subjects. I hope other universities follow their example and provide some free courses. I have worked with Friction welding and can assure you that it is not as easy as some of those links make it out to be. Using a belt driven mill is not the way to go. A gear driven head will give you what you need but again it is not for the faint of heart. I'm a bit of a lunatic when it comes to milling so it was nice for me to try it out. I still prefer MIG and Stick when I need to weld and will probably try to get into welding more myself at some point.
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Postby Tiahaar » Mon Mar 19, 2007 10:21 pm

Wow I'll echo everyone elses praises, you're awesome Toolmaker! Thanks!
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Postby dragonfly Jafe » Mon Mar 19, 2007 10:27 pm

....dammit! Now I want to go out and weld something! Damn you ToolMaker! Damn You!
Talent hits a target no one else can hit; Genius hits a target no one else can see.
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Postby robotland » Tue Mar 20, 2007 5:54 am

Ditto. I can't even START reading those links right now, until I've finished what I'm working on...But I DID pull the oxyace rig out for the Spring!
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Postby BAS » Tue Mar 20, 2007 4:00 pm

Darn, now that you started this thread, it does occur to me that learning to weld could be quite useful! :shock: Now, when am I going to find the time, money, and other resources....? :wink:


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Do things that have never been done."
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Postby Toolmaker » Mon Apr 16, 2007 5:29 pm

Removing rust from salvaged materials can be done with Electrolytic rust removal. The following links will have instructions and illustrations. This process is really quite easy and safe as long as directions are followed precisely.

http://www.davidbradley.net/ERR.html
http://www.htpaa.org.au/article-electro.php
http://www.stovebolt.com/techtips/rust/ ... usting.htm
http://www3.telus.net/public/aschoepp/e ... crust.html
http://www.instructables.com/id/E17UQMY28PEQ6T2A5Z/

As always some of these websites have more information on related subjects.
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Postby Toolmaker » Fri Jul 27, 2007 3:36 am

Only a month left for everyone to spark up on their skills!
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Postby spectabillis » Fri Jul 27, 2007 6:02 am

so here's a quick question - i got tired of the splatter and having pore problems in my flux-core mig so i started using normal wire without gas. anyone else ever tried this? solved splatter but only helped a little bit with micro holes, and its still a bitch to weld thin stainless without burnthroughs.
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Postby Toolmaker » Fri Jul 27, 2007 3:00 pm

spectabillis wrote:so here's a quick question - i got tired of the splatter and having pore problems in my flux-core mig so i started using normal wire without gas. anyone else ever tried this? solved splatter but only helped a little bit with micro holes, and its still a bitch to weld thin stainless without burnthroughs.


Use gas 90 percent helium, 8 percent argon and 2 percent CO2. NEVER try to weld thin stainless with flux core. Flus core uses more heat because of globular transfer. Unlike short arc, where the weld puddle cools every time the wire touches the base metal, the arc remains "on" constantly with globular transfer. You also want to try to use the "thinnest" wire possible and feed by hand. Also keep try to keep the heat down to avoid the HAZ/burnthroughs. For long welds like around a thin cylinder try welding an inch than skipping 4 or 5, sometimes called skip welding. Not sure if you tried this but heres another tip.. keep to the middle of the puddle instead of the edge like you normally do, this will allow the puddle to protect your base metal. One final tip would be to increase cooling of your work with a piece of metal to act as a heatsink. Basically any piece of copper or aluminum near your HAZ should do the trick. If this is not possible than you can try to weld in a colder room. And on a final note try feeding the wire by hand.
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Postby spectabillis » Fri Jul 27, 2007 3:56 pm

thanks for the followup. problem is i tried most of that except using gas because its a flux-core welder, no gas support. but knowing flux core is a slightly hotter weld is helpful.

but i have to wonder about holding it longer in place, when i do that the wire makes a serious pit with a large nipple on the inside. in other words, it pushes the wire to the bottom and cools like that with a weak side of the pit or hole.
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Postby Toolmaker » Fri Jul 27, 2007 10:45 pm

spectabillis wrote:thanks for the followup. problem is i tried most of that except using gas because its a flux-core welder, no gas support. but knowing flux core is a slightly hotter weld is helpful.

but i have to wonder about holding it longer in place, when i do that the wire makes a serious pit with a large nipple on the inside. in other words, it pushes the wire to the bottom and cools like that with a weak side of the pit or hole.


There is only so much one can get away with. Two of the most important factors with thin stainless is 1) No Flux core and 2) tri-mix gas. ESAB has some information somewhere on one of the "course" webpages. I might have missed something since I'm more of a metal cutter rather than joiner. Also is your worst spot where you start your bead? Sometimes the smallest shit can fuck with ya.. like trying to snip the end of your wire instead of grinding a point.
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Postby Toolmaker » Thu Sep 20, 2007 11:49 pm

FSW in action

[youtube]http://www.youtube.com/watch?v=niVsJPFlg1Y[/youtube]

Thermite in action

[youtube]http://www.youtube.com/watch?v=nR6K90cR8Lg[/youtube]
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Hadn't seen this thread before, thanks for the bump!

Postby honeyfire » Fri Sep 21, 2007 10:53 am

Honey, you just about got me wet with all this hot gorgeous welding info!

















No, i don't mean that figuratively, either.
Welding = sexy.
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Postby skibear » Wed Sep 26, 2007 10:01 am

Thermite in action is a totally awesume use of flames.

Stand Back !

Not very controllable, though, best for railroad rails and
very heavy metal projects only.
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Postby Toolmaker » Wed Sep 26, 2007 2:06 pm

by hand
[youtube]http://www.youtube.com/watch?v=9P_QhTOnknQ[/youtube]

by hand with a coathanger
[youtube]http://www.youtube.com/watch?v=_FARfmZINJY[/youtube]
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Postby regionalchaos » Fri Sep 28, 2007 9:59 pm

By sledge hammer!

[youtube]http://www.youtube.com/watch?v=E7bnffUHYUI[/youtube]
Participate! - )'( -

http://regionalchaos.net
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