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عدد المساهمات : 19002 التقييم : 35506 تاريخ التسجيل : 01/07/2009 الدولة : مصر العمل : مدير منتدى هندسة الإنتاج والتصميم الميكانيكى
| موضوع: كتاب Welding For Dummies الجمعة 08 نوفمبر 2024, 10:46 pm | |
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أخواني في الله أحضرت لكم كتاب Welding For Dummies by Steven Robert Farnsworth
و المحتوى كما يلي :
Contents at a Glance Introduction 1 Part I: Understanding Welding Basics . 7 Chapter 1: Diving Into the World of Welding .9 Chapter 2: Considering Commonly Welded Metals .19 Chapter 3: Setting Your Sights on Welding Safety .33 Chapter 4: Setting Up Your Welding Shop 53 Part II: Welding on a Budget: Stick and Tig Welding 71 Chapter 5: Getting on the Stick: Understanding Stick Welding 73 Chapter 6: Getting to Work with Stick Welding .85 Chapter 7: To Tig or Not To Tig: Understanding Tig Welding .105 Chapter 8: Trying Out Tig Welding 119 Part III: Discovering Mig Welding . 133 Chapter 9: Understanding the ABCs of Mig Welding .135 Chapter 10: Practicing Mig Welding 147 Part IV: Getting Fancy: Plasma Cutting, Oxyfuel Cutting, and Other Processes 157 Chapter 11: Examining Plasma and Oxyfuel Cutting .159 Chapter 12: Ready, Set, Cut! Trying Out Plasma Arc Cutting and Oxyfuel Cutting 173 Chapter 13: Exploring Special Weld Processes 187 Chapter 14: Exploring Pipe Welding 205 Chapter 15: Working with Cast Iron 217 Part V: Putting Welding into Action with Projects and Repairs . 229 Chapter 16: Two Welding Projects to Boost Your Welding Shop 231 Chapter 17: Constructing a Campfire Grill 249 Chapter 18: Fixin’ to Fix Things: Analyzing and Planning .257Part VI: The Part of Tens 273 Chapter 19: Ten Tools Every Welder Wants 275 Chapter 20: (Not Quite) Ten Advantages of Being a Certified Welder 285 Chapter 21: (Almost) Ten Welding Defects 291 Chapter 22: Ten Signs You’re Welding Correctly 301 Chapter 23: Ten Maintenance Tips for Your Welding Equipment and Shop .307 Glossary 319 Index 343Table of Contents 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 I: Understanding Welding Basics .3 Part II: Welding on a Budget: Exploring Stick and Tig Welding 4 Part III: Discovering Mig Welding .4 Part IV: Getting Fancy: Plasma Cutting, Oxyfuel Cutting, and Special Processes .4 Part V: Putting Welding into Action with Projects and Repairs .4 Part VI: The Part of Tens .5 Icons Used in This Book .5 Where to Go from Here .5 Part I: 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 10 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 .17 Looking at the Future of Welding 18xii Welding For Dummies 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 fi re 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 fl ammable 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 53 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 61 Selecting your welding machine 62 Considering a few accessories for your welding shop 67Table of Contents xiii Part II: 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 .73 Understanding the Factors That Infl uence Stick Welding 75 Getting Familiar with Stick Welding Equipment 76 Discovering the differences among stick welding machines .76 Setting up your stick welding machine .79 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 106 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 .111 Thinking about tig torches .112 Selecting and managing shielding gas .112 Controlling current and amperage 115 Selecting filler metal 116 Exploring tungsten electrodes .117 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 123xiv Welding For Dummies Matching Materials and Settings .124 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 III: 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) 139 Mig welding machines .140 Mig welding guns .140 Electrode wire feeders 141 Sifting through Shielding Gases for Mig Welding 142 Taking a Look at Electrode Wire 143 Adjusting Mig Equipment to Suit your Mig Welding Project 145 Chapter 10: Practicing Mig Welding . . . . . . . . . . . . . . . . . . . . . . . . . . .147 Preparing to Mig Weld 147 Getting the equipment ready .148 Setting the wire feed speed and voltage .150 Trying Out Mig Welding 151 Making vertical mig welds 154 Joining pieces of sheet metal .155 Watching Out for Common Mig Welding Defects 155 Part IV: Getting Fancy: Plasma Cutting, Oxyfuel Cutting, and Other Processes . 157 Chapter 11: Examining Plasma and Oxyfuel Cutting . . . . . . . . . . . . . .159 Understanding Plasma Arc Cutting .159 Identifying some good materials for plasma cutting .160 Taking a look at plasma cutting’s advantages and disadvantages .161 Perusing and Preparing Plasma Arc Cutting Equipment 162 Getting a handle on plasma cutting equipment .162 Setting the equipment up properly .164Table of Contents xv Exploring Oxyfuel Cutting Basics 165 Considering what you can (and can’t) cut with oxyfuel .165 Looking at the pros and cons of oxyfuel cutting .166 Checking Out and Setting Up Oxyfuel Cutting Equipment .166 Examining oxyfuel cutting equipment .167 Deciding among different gas cylinder sizes 169 Setting up oxyfuel cutting equipment .170 Chapter 12: Ready, Set, Cut! Trying Out Plasma Arc Cutting and Oxyfuel Cutting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .173 Exploring Plasma Arc Cutting 173 Slicing a straight line .174 Cutting a circle .176 Creating a bevel .177 Practicing Oxyfuel Cutting 178 Lighting the torch 179 Making a straight cut .181 Cutting out a circle 183 Taking on a beveled edge .184 Chapter 13: Exploring Special Weld Processes. . . . . . . . . . . . . . . . . .187 Working through the Basics of Welding with Gas .187 Taking a gander at gas cylinders .188 Looking at more gas welding equipment 189 Getting to work with gas welding 191 Discovering Brazing (Braze Welding) .195 Keeping a few brazing rules in mind .195 Giving brazing a try .195 Finding Out about Fusion Welding 197 Soldering On: Exploring Soldering 199 Following the rules of soldering .200 Understanding the two types of soldering .202 Trying the soldering process .202 Chapter 14: Exploring Pipe Welding. . . . . . . . . . . . . . . . . . . . . . . . . . . .205 Delving into the Different Kinds of Pipe .206 Getting Down to Welding Steel Pipes 206 Getting set up and preparing the pipe 207 Making the tacks 209 Welding the pipes 210 Trying some other angles .212 Peeking at a Few More Types of Pipe Welding Joints .214 Keeping an Eye Out for Common Pipe Welding Defects .214xvi Welding For Dummies Chapter 15: Working with Cast Iron . . . . . . . . . . . . . . . . . . . . . . . . . . . .217 Casting Light on the Three Most Common Types of Cast Iron .217 Gray cast iron .218 Malleable cast iron 218 Nodular cast iron .219 Getting the (Cast) Iron in the Fire: Welding Gray Cast Iron .221 Stick welding cast iron 221 Oxyfuel welding cast iron .224 Mig welding cast iron 227 Part V: Putting Welding into Action with Projects and Repairs . 229 Chapter 16: Two Welding Projects to Boost Your Welding Shop . . .231 Creating a Torch Cart 231 Gathering the materials 233 Acquiring the right steel pieces .233 Measuring and cutting pieces 234 Making the welds .236 Adding the wheels .240 Checking your welds .241 Picking out your paint .242 Fabricating Your Own Portable Welding Table .242 Rounding up your tools 243 Picking out the parts .243 Assembling the pieces .244 Ensuring smooth edges .247 Choosing your paint 248 Putting on the wheels 248 Chapter 17: Constructing a Campfi re Grill . . . . . . . . . . . . . . . . . . . . . . .249 Fabricating a Campfire Grill .249 Getting your tools in order .249 Obtaining the proper steel pieces .250 Cutting the steel pieces to length 251 Welding the grill .253 Picking out your paint .256 Seasoning the cooking surface .256 Chapter 18: Fixin’ to Fix Things: Analyzing and Planning. . . . . . . . . .257 Determining Whether Something Is Fixable .258 Planning a Repair Strategy .259 Identifying the metal and what it means for the repair 260 Deciding which welding process to use for your repair .264 Making and following your plan .265Table of Contents xvii Getting Ready to Make Repair Welds 266 Preparing your repair piece and work area .266 Gathering your equipment and tools 267 Selecting fi ller rods and electrodes .268 Considering Cracks .269 Part VI: The Part of Tens . 273 Chapter 19: Ten Tools Every Welder Wants . . . . . . . . . . . . . . . . . . . . .275 41⁄2-Inch Grinder 276 Hacksaw 276 Air Compressor 277 3⁄8-Inch Electric Drill 277 Wrench Set .278 Steel Sawhorses .278 Cutoff Saw .280 Bench Grinder 281 Bottle Jack 282 Toolbox .282 Chapter 20: (Not Quite) Ten Advantages of Being a Certifi ed Welder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .285 More Job Opportunities 286 Better Pay .286 More Chances for Advancement .287 Certifi cation that Travels with You .288 Ability to Join a National Organization .288 Qualifi cation in Specifi c Areas of Welding 289 Increased Confi dence in Your Welding Skills 289 Listing in the American Welding Society Database .290 A Head Start on Additional Types of Welding Certification .290 Chapter 21: (Almost) Ten Welding Defects . . . . . . . . . . . . . . . . . . . . . .291 Incomplete Penetration 291 Incomplete Fusion .292 Undercutting 293 Slag Inclusions .294 Flux Inclusions .295 Porosity .296 Cracks .297 Warpage 298 Spatter .299xviii Welding For Dummies Chapter 22: Ten Signs You’re Welding Correctly . . . . . . . . . . . . . . . . .301 The Weld Is Distributed Equally between Parts 301 The Slag or Shielding Material Doesn’t Stick to the Weld 302 No Holes or Irregularities on the Weld Surface .302 The Weld Is Tight .303 The Weld Is Leakproof 303 The Weld Has Full Penetration 304 The Weld Has No Undercutting .304 The Weld Has No Overlap 304 The Weld Meets Strength Requirements 305 You’re Safe and Healthy 305 Chapter 23: Ten Maintenance Tips for Your Welding Equipment and Shop . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .307 Checking on Your Hand Tools .307 Taking Care of Power Tools .309 Doing Basic Housekeeping in the Shop 310 Protecting Your Welding Helmet .310 Seeing to Stick Welding Machine Maintenance .311 Working on Maintaining Your Mig Welding Machine .312 Tuning Up Your Tig Welding Machine 314 Taking Care of Your Oxyfuel Equipment 315 Keeping Your Air Compressor Working .316 Drill Press Maintenance 316 Glossary 319 Index . 343 Index • A • AC (alternating current), 91, 115, 319 acetone, 25, 319 acetylene, 319 acetylene cylinders, 188, 192 acid, in cleaning steel, 25 advancement, welding career, 287 air compressors cost, 68 maintenance, 316 with plasma arc cutting, 174 uses, 277 air-acetylene, 319 air-arc cutting, 319 alcohol, in cleaning steel, 25 alloys, 261, 319 alternating current (AC), 91, 115, 319 aluminum. See also metals alloy 3003, 30 alloys, 29 butt joint, 130 characteristics, 14 color test, 261 lap joint, 131 mig welding, 30 plasma arc cutting, 175–176 properties, 29–30 pure, 29, 30 repairs, 262 stick welding, 30 T joint, 132 tig welding, 30, 108, 125 welding process decision, 264 welding techniques, 30 working with, 29–30 American Welding Society (AWS) certifications. See also certified welder advantages, 286–290 defined, 285 as national organization, 288 pursuing, 285 skill demonstration, 286 in specifi c welding areas, 289 as traveling certification, 288 ammeters, 319 amperage adjusting after starting, 92 defined, 90 high, as defect cause, 294 low, as defect cause, 292, 293, 295 setting, 90, 91–92, 97 stick welding, 75, 90, 91–92 tig welding, 115 angle grinders, 24 angle irons campfi re grill project, 252 portable welding table project, 245, 247 torch cart project, 237–238 annealing, 187, 319 anvils, 68 arc blow, 81, 319 arc brazing, 319 arc cutting, 319 arc eye, 46 arc length, 75, 94, 319 arc striking, 93–95, 319 arc welding, 319 argon, 114, 142 austenite, 320 auto-darkening lenses, 35 autogenous welds, 116 AWS. See American Welding Society certifications • B • back pass, 320 back up, 320 back welds, 320 backfi re, 180, 320 backhand welding, 320 backing rings, 208, 320 backing strips, 320344 Welding For Dummies backstep, 320 back-up strips, 267 ball-peen hammers, 58, 60 base metal arc welding, 320 base metals brazing, 195 defined, 320 postheating, 271 preheating, 271 in repairs, 265 bead welds, 320 beads, 320, 340 beanies, 38 bench grinders. See also grinders abrasive wheels, 281 defined, 281 gloves and, 282 illustrated, 281 sharpening tools with, 282 bevels defined, 321 oxyfuel cutting, 184–185 plasma arc cutting, 177–178 billets, 321 birds’ nest defined, 312 fixing, 314 illustrated, 313 bleeding wound/injuries, 49 bonds, 321 bones, broken, 49 boots, 38 bottle jacks, 282, 309 box-end wrenches, 278 brass/bronze, color test, 261 brazing base metals, 195 block, 321 butt joint, 195 cast iron, 226 corncob, 195, 197 defi ned, 17, 195, 321 dip, 324 fi ller rods, 195, 196 fi re bricks, 196 fl ux inclusions, 295 furnace, 327 induction, 329 lap joint, 195 passes, 196–197 process, 196–197 quenching metal, 196 resistance, 334 rules, 195 torches, 196, 197, 339 bridging, 321 buckling, 321 build-up sequence, 321 burns chemical, 52 fi rst-degree, 50, 51 fl ash, 46, 326 heat, 50–51 risk, reducing, 47 second-degree, 50, 51 third-degree, 50, 51 butt joints. See also joints brazing, 195 defi ned, 129, 321 fusion welding, 198 illustrated, 130 pipe welding, 207 tig welding process, 130 butt welds, 321 butter welds, 321 • C • cable holders, 67 campfire grill angle irons, 252 characteristics, 249 fabricating, 249–256 grill grate, premade, 251 grill grate assembly, 255 grill grate pieces, 253 illustrated, 250 paint, 256 partially constructed, 255 seasoning, 256 steel pieces, 250–251 tack welds, 253 tools for, 249–250 welding, 253–256 capillary action, 321 carbide precipitation, 321 carbon, in steel, 13 carbon dioxide, 142Index 345 carburizing fl ame, gas torch, 193, 322 cascade sequence, 322 case hardening, 322 cast iron brazing, 226 carbon content, 217 color test, 260 defined, 217 fi ller rods, 225 graphite, 218 gray, 218 malleable, 218–219 mig welding, 227–228 nodular, 219 oxyfuel welding, 224–226 repair welds, 263 repairs on, 262 stick welding, 221–223 welding process decision, 264 working with, 217–228 C-clamps, 309 CDA (Copper Development Association), 262 center punches in punching measurement lines, 236 in punching soapstone marks, 241 for repairs, 268 certified welder advancement, 287 AWS database listing, 290 becoming, 285–286 job opportunities, 286 pay, 286–287 skill confidence, 289 in specifi c areas, 289 chamfering, 322 chemicals burns, 52 cleaning steel with, 25 MSDS for, 25, 39 chipping, with stick welding, 75 chipping hammers, 58, 60, 308 chisels, 308 circles oxyfuel cutting, 183–184 plasma arc cutting, 176–177 cleaning steel, 23–25 with stick welding, 74, 75 work space, 41 clothing, protective, 38–39 coalescence, 322 cold cracks, 297 cold rolled steel, 21 color test, 260–261 combination squares, 83 concavity, 322 concurrent heating, 322 cone, 322 contaminated tungsten, 121–122 conventions, this book, 2 convexity, 323 copper color test, 260 repairs, 262 tig welding, 108 uses, 31 welding process, 31 welding process decision, 264 Copper Development Association (CDA), 262 corncob, 195, 197 corner joints, 323 corrosion aluminum and, 14 defined, 323 stainless steel and, 13 steel and, 13 coveralls, 81 covered electrodes, 93 cracking the cylinders, 191 cracks. See also defects cold, 297 crater, 297, 323 defined, 323 fixing, 271 hot, 297 illustrated, 270, 297 preventing, 271 reasons for, 270 in repair welding, 269–271 root, 334 stainless steel tig welds, 108 subsurface, 269 toe, 339 underbead, 340 crater cracks, 297, 323 creeper gauge, 315 creepers, 68346 Welding For Dummies crescent wrenches, 58, 60 cup holders, 67 current, welding machines, 62, 115 cutoff saws, 280–281 • D • DC (direct current), 91, 115, 324 defects cracks, 269–271, 297 defined, 323 fl ux inclusions, 295–296 incomplete fusion, 156, 215, 292–293 incomplete penetration, 156, 215, 291–292 mig welding, 155–156 pipe welding, 214–215 porosity, 296 slag inclusions, 294–295 spatter, 15, 152, 208, 299 undercutting, 293–294 warpage, 298 deoxidizers, 109 deposited material, 323 deposition efficiency, 323 die, 324 die welding, 324 direct current (DC), 91, 115, 324 distortion, 236 downhill vertical mig welds, 154 drill presses, 69, 316–317 dross, 182 ductile iron. See nodular cast iron ductile joints, 107 ductility, 12, 22, 324 duty cycle defi ned, 62, 324 stick welding machines, 77 dye-penetrating test, 324 • E • edge joints, 325 electric drills, 277–278 electric shock safety, 45–46 victims, 50 electrical conductivity, 12, 22 electrical setback, 164 electrode holders, 82, 92, 325 electrode stubs defined, 45 safety, 45 stick welding, 75 electrode wire. See also mig welding carbon steel classifications, 144 cutting end of, 148 defined, 143 feed speed, 150–151 feeders, 141 liner, 148 purchasing, 144 selection, 151 size, 143 stub off, 153 electrodes bare, 320 coated, 322 composite, 322 consumable, 322 defined, 325 dirty, 270 low hydrogen, 268–269 for repairs, 267 stick welding, 16, 74, 75, 80–81, 87–90 tig welding, 106, 112, 117, 120–122 equal pressure torches, 189 equipment. See also welding shops air compressor, 68, 174, 277, 316 anvil, 68 ball-peen hammer, 58, 60 checking, 47 chipping hammer, 58, 60 creeper, 68 crescent wrench, 58, 60 drill press, 69 grinder, 69, 222, 247, 276, 281–282 hacksaw, 69, 276, 308 hand tools, 58–60 level, 58, 60 maintaining, 47–48 mig welding, 139–141 options, 57 pliers, 59Index 347 portable welding curtain, 69 soapstone/silver pencils, 59 steel square, 59, 60 stick welding, 76–83 straightedge, 59, 60 tape measure, 59, 267, 307 tig welding, 110–117 types of, 56–69 used, 58 vise, 69 vise grips, 59, 308 welding machine, 62–67 welding table, 61–62 wire brush, 60, 241, 308 etching, 325 eye injuries, 52 eye protection. See also gear, safety; safety for bystanders, 35 welding helmet, 34–35 • F • fabricating campfi re grill, 249–256 defined, 10 metal products, 10 portable welding table, 242–248 torch cart, 231–242 fast fi ll electrodes, 268 fast freeze electrodes, 268 faying surface, 325 FCAW (fl ux core arc welding), 135, 326 ferrite, 325 ferrous metal, 261 fi eld welds, 325 fi ller metal, 116–117 filler rods brazing, 195, 196 cast iron, 225 common, 123 defi ned, 116, 123, 190, 341 fusion welding, 197, 199 gas welding with, 190, 194, 269 illustrated, 116 nonferrous, 195 for repairs, 267, 269 RG-45, 269 RG-60, 269 RG-65, 269 tig welding with, 123 fi llet welds, 325 fi re bricks, 196 fire extinguishers. See also gear, safety; safety classes, 36, 37 cutting down on need for, 36 illustrated, 37 fi res, clothing, 50 fi rst-aid kits, 48–49 fl ame hardening/softening, 326 fl ammable gases, 44 fl ammable liquids, 43–44 fl ash burns, 46, 326 fl ash welding, 326 fl ashback, 180, 326 fl ashback arrestor, 315 fl at position, 326 fl at steel, 20, 21 flat surface pipe welding on, 212–213 stick welding on, 96–97 fl ow meters, 113, 148 fl ow welding, 326 flux correct, using, 201 defi ned, 93, 201, 202, 326 on electrodes, 93 illustrated, 202 in oxyfuel cast iron welding, 225 in soldering, 201, 202 soldering paste, 201, 202 fl ux core arc welding (FCAW), 135, 326 flux inclusions. See also defects avoiding, 296 defined, 295 illustrated, 295 forehand method defined, 326 fusion welding, 198 gas welding, 194 forge welding, 326 friction lighters, 190 fuel gases, 165 full feeders, 141348 Welding For Dummies fusion, 327 fusion welding butt joint, 198 defined, 197 fi ller rods, 197, 199 forehand method, 198 illustrated, 198 process, 198–199 torch, 198 welds, 199 with/without fi ller rods, 197 • G • gas cylinders. See also oxyfuel cutting acetylene, 188, 192 caps, 191 defi ned, 168, 323 gas welding, 188 large size, 170 leaking, 188 left-handed fittings, 188 moving, 188 oxyfuel cutting, 168, 169–170 oxygen, 188, 191 right-handed fittings, 188 selecting, 169–170 setting up, 170–171 shielding gas, 112 small size, 170 in torch cart, 232 valves, opening/closing, 191 gas metal arc welding (GMAW). See mig welding gas torches acetylene valve, 194 for annealing, 187 body, 189 carburizing fl ame, 193, 322 equal pressure, 189 fuel valve, 192 lighting, 192–193 neutral fl ame, 192–193, 330 oxidizing fl ame, 193, 331 oxygen valve, 192 processes with, 187 setting up, 191–192 soldering with, 202 tips, 190 gas tungsten arc welding (GTAW). See tig welding gas welding acetylene cylinder, 188 defi ned, 187, 327 equipment leaks, 42 fi ller rods, 190, 194, 269 fi nishing up, 194 forehand method, 194 friction lighter, 190 gas cylinders, 188, 191 gases, 187 goggles, 190 hoses, 190 oil/grease and, 190 oxyacetylene gas, 187 oxygen cylinder, 188 oxymapp, 187 position, 194 propane, 187 regulators, 190, 191 welds, 194 working with, 191–194 gases fuel, 165 inert, 329 inhalation, 50 oxyacetylene, 187 oxymapp, 187 safety, 43–44 shielding (mig welding), 142–143 shielding (tig welding), 106, 109, 112–115, 122–123 gear, safety eye protection, 34–35 fi re extinguishers, 36–37 Material Safety Data Sheets (MSDS) and, 39 protective clothing, 38–39 respirators, 39–40 generators, stick welding machine, 77, 78 globular transfer, 137, 327 gloves, 38, 82 GMAW (gas metal arc welding). See mig welding goggles, 190, 327 grapes, 210 gray cast iron defined, 218 determination, 219Index 349 mig welding, 227–228 oxyfuel welding, 224–226 repairs on, 262 stick welding, 221–224 welding, 221–228 grill grate. See also campfire grill assembly, 255 pieces, 253 premade, 251 seasoning, 256 welds, 254 grinders bench, 281–282 cost of, 276 defined, 69 as dynamic tools, 276 41/2-inch, 276 for repairs, 267 sanding discs, 247 for V-shaped grooves, 222 grinding pipe, 208 portable welding table, 247 torch cart welds, 241 tungsten electrodes, 121 groove welds, 327 grooves, 222, 292, 327 ground clamps, 82, 175, 176, 177 GTAW (gas tungsten arc welding). See tig welding guided bend test, 328 • H • hacksaws, 69, 276, 308 hammers, 307 hand tools, 58–60 hardfacing, 263, 328 hardness, 22 hats, 38 heart attack, 50 heat burns, 50–51 heat sink, 328 heat sparks, 74 heat treating, 328 heating gate, 328 helium, 114, 142 helmets, welding comfort, 35 lenses, 35 maintenance, 35, 310–311 need for, 34–35 in oxyfuel cutting, 179, 181 shade number, 35 stick welding, 81 high carbon steel, 20 high pressure pipes, 206 history, welding, 11 horizontal position, vertical pipe welding in, 213 horizontal stick welding defined, 101 fl at surface welding versus, 101 illustrated, 102 starting, 101 hoses as leak source, 42 oxyacetylene, 179, 190 oxyfuel cutting, 168 hot cracks, 297 hot pass, 213 hot rolled steel, 21 hot short, 328 hydrogen, in welds, 270 • I • icicles, 210 icons, this book, 5 impact test, 329 impregnated tape metal arc welding, 329 incomplete fusion. See also defects causes, 293 defined, 292 illustrated, 293 mig welding, 156 pipe welding, 215 incomplete penetration. See also defects causes, 292 defined, 291 illustrated, 292 mig welding, 156 pipe welding, 215 indoor welding, 55–56350 Welding For Dummies induction welding, 329 injuries. See also safety bleeding/wounds, 49 broken bones, 49 burns, 50–52 clothing fires, 50 electric shock, 50 eye, 52 fi rst-aid kits, 48–49 gas inhalation, 50 handling, 49–52 heart attack, 50 plume poisoning, 52 poisons, 50 stick welding, 87 inverters, 79 iron powder, 88 • J • job opportunities, certifi ed welder, 286 joints butt, 129, 130, 195, 198, 207 composite, 322 corner, 323 defined, 329 ductile, 107 edge, 325 lap, 130–131, 155, 195, 329 lateral, 214 repair, 265–266 root of, 335 socket, 214 T, 131–132, 214, 338 Y, 214 • K • kerf, 235, 329 keyholes, 211, 213, 329 • L • lap joints. See also joints brazing, 195 defi ned, 130, 329 illustrated, 131 mig welding sheet metal, 155 tig welding process, 131 lateral T and Y joints, 214 layers, 212, 329 lead, color test, 261 leaks checking for, 42 gas cylinders, 188 hose, 42 leather aprons, 39 leather jackets, 38 left-handed fi ttings, gas cylinders, 188 levels, 58, 60 lighting, for repairs, 267 liquidus, 329 local preheating, 330 low carbon (mild) steel, 20 low hydrogen electrodes, 268–269 low pressure pipes, 206 • M • magnesium tig welding, 108 uses, 31 welding process, 31 magnetism, 22 magnetism check, 261 maintenance tips air compressor, 316 drill press, 316–317 hand tools, 307–309 mig welding machines, 312–314 oxyfuel equipment, 315 power tools, 309–310 shop housekeeping, 310 stick welding machine, 311–312 tig welding machines, 314–315 welding helmet, 310–311 malleable cast iron. See also cast iron color test, 260 defined, 218 determination, 219 expense, 219 manifolds, 330Index 351 martensite, 330 mash seam welding, 330 Material Safety Data Sheets (MSDS) for hazardous materials, 39 reading and understanding, 25 measurement lines, center punching, 236 marks, drawing, 236 for torch cart project, 235–236 medium carbon steel, 20 medium pressure pipes, 206 melting point, 22, 330 melting range, 330 melting rate, 330 metal identification aluminum, 262 cast iron, 262 with color chart, 260–261 copper, 262 kit, 261 magnetism check, 261 spark test, 220, 261 metallizing, 330 metals. See also specific metals brazing, 195 characteristics, 12 ductility, 12, 22 electrical conductivity, 12, 22 ferrous, 261 fi ller, 116–117, 325 hardness, 22 hot, handling, 47 magnetism, 22 melting point, 22 nickel-based alloys, 31 nonferrous, 261, 331 for oxyfuel cutting, 165 parent, 293 for plasma arc cutting, 160 precious, 31 properties, 12, 22 quenching, 196 resistance to oxidation, 22 strength, 12, 22 for tig welding, 108–109 mig welding advantages, 138–139 aluminum, 30 beads, 152, 153 benefits, 16 defects, 155–156 defi ned, 16, 135, 330 drawbacks, 16, 139 electrode wire feeders, 141 equipment, 139–141 equipment, readying, 148–149 feed speed, 145, 150–151 globular transfer, 137, 327 how it works, 16–17, 136–137 joining pieces of sheet metal, 155 penetration, 139 practicing, 147–156 preparing for, 147–151 pulse transfer, 137 robotic, 137 settings, experimenting with, 153–154 setup, 140 shielding gases, 142–143 short circuit transfer, 136, 150 spray arc transfer, 136–137, 150–151 stainless steel, 28, 150, 151 steel, 26 voltage, 145, 150–151 mig welding (cast iron) on cracked cast iron, 227 illustrated, 228 mig gun, 228 process, 227–228 shielding gas, 227 weld backing, 227 mig welding guns defined, 140–141 liner, 312, 313 moving, 152 mig welding machines birds’ nest, 312, 313, 314 DC option, 140 defined, 65 design, 65 illustrated, 66 liner, 312, 313 maintenance, 312–314 power needs, 66 prices, 140 types of, 140 mixing chamber, 330352 Welding For Dummies monel metal, color test, 261 MSDS. See Material Safety Data Sheets multi-impulse welding, 330 • N • neutral fl ame, gas torch, 192–193, 330 new welding machines, 63 nick break test, 330 nickel, color test, 261 nickel-based alloys, 31 nitriding, 330 nodular cast iron, 219 nonferrous fi ller rods, 195 nonferrous metal, 261, 331 normalizing, 331 nozzle tip, plasma cutting torch, 164 nugget, 331 • O • Occupational Outlook Handbook (OOH), 286 1G horizontal rolled open root pipe weld, 212 open circuit voltage, 331 open-end wrenches, 278 organization, this book, 3–5 OSHA (Occupational Safety and Health Administration) Web site, 43 outdoor welding, 56 output rating, stick welding machines, 77 overhead stick welding. See also stick welding checking clothes and, 104 defi ned, 102, 331 illustrated, 103 process, 102–103 oxidizing fl ame, gas torch, 193, 331 oxyacetylene cutting/welding, 331 oxyacetylene gas, 187 oxy-arc cutting, 331 oxyfuel cutting acetylene levels, 181 actions to avoid, 179 advantages, 166 beveled edges, 184–185 circles, 183–184 cutting tip, 169 defi ned, 18, 165 drawbacks, 166 dross, 182 equipment, 166–171 equipment setup, 170–171 friction lighter, 168 fuel gas, 165 gas cylinders, 168, 169–170 hoses, 168 ignition temperature, 165 metals, 165 oxygen levels, 181 practicing, 178–185 regulators, 168, 171 safety, 179 setup illustration, 167 straight lines, 181–182 welding helmet, 179, 181 oxyfuel cutting torches backfi re, 180, 320 flashback, 180 illustrated, 168, 180 lighting, 179–180 maintenance, 315 operating, 180–181 shutting off, 181 oxyfuel welding (cast iron) choice of, 224 fi ller rods, 225 flux, 225 items needed for, 224 process, 225–226 setup, 224 torch tip, 225 oxygen cutting, 331 oxygen cylinders, 188, 191 oxygen gouging, 331 oxy-hydrogen cutting/welding, 331–332 oxymapp, 187 oxy-natural gas cutting, 332 oxy-propane cutting, 332Index 353 • P • paint campfi re grill project, 256 portable welding table project, 248 for repairs, 268 torch cart project, 242 pants, 38 parent metal, 293 parts cart. See portable welding table passes, 332 passive lenses, 35 pay, certifi ed welder, 286–287 peening, 332 penetration defined, 304 full, 304 incomplete, 156, 215, 291–292 joint, 329 root, 335 percussive welding, 332 perlite, 332 piece failure. See also repairs improving pieces to avoid, 265 mechanical failures causing, 265 reasons for, 258 pipe clamps, 209 pipe welding backing rings, 208, 320 butt joint, 207 defects, 214–215 in fl at position, 212–213 grapes, 210 hot pass, 213 incomplete fusion, 215 incomplete joint penetration, 215 keyholes, 211, 213, 329 lateral T and Y joints, 214 movement in, 212 pipe types and, 205, 206 process, 210–212 root pass, 210–211, 213 side-to-side motion, 212 socket joints, 214 standards, 215 tacks, 209–210 undercutting, 211 vertical, in horizontal position, 213 pipes aligning, 208 diameter, 209 grinding, 208 high pressure, 206 low pressure, 206 medium pressure, 206 Schedule 40, 207 setting up and preparing, 207–209 steel, 205 tacked, 213 wall thickness, 209 plasma arc cutters illustrated, 163 regulatory assembly, 163 setting up, 164 torch connection, 163 types of, 174 plasma arc cutting advantages, 161 air flow, 174 aluminum, 175–176 bevels, 177–178 characteristics, 160 circles, 176–177 defined, 159–160 diagram, 162 drawbacks, 161 equipment setup, 164 materials, 160 pilot arc, 175 preparing for, 162–164, 174 regulator, 174 straight lines, 174–176 plasma cutting torches angling, 177–178 connection, 163 electrode tip, 164 nozzle, 193 nozzle insulator, 164 nozzle tip, 164 trigger, 175, 176, 177354 Welding For Dummies plating, 332 platinum, welding, 31 pliers, 59, 308 plug welds, 332 plume poisoning, 52 poisons swallowed, 50 poke welding, 332 polarity alternating current (AC), 91 defined, 333 direct current electrode negative (DC- or DCEN), 91 direct current electrode positive (DC+ or DCEP), 91 reverse, 334 setting, 90, 91 stick welding machines, 64, 76–77 straight, 337 porosity, 109, 296, 312 portable welding curtains, 69 portable welding table angle irons, 245, 247 assembly, 244–247 castors, 244, 248 defined, 242 dimensions, 242 edges, smooth, 247 fabricating, 242–248 illustrated, 243 paint, 248 partial construction illustration, 246 parts, 243–244 parts illustration, 245 tack welds, 244 tools for, 243 washer welding position, 246 post-fl ow timers, 112 postheating, 333 power source defined, 62 stick welding machine, 77–79 power tool maintenance, 309–310 precious metals, 31 pre-fl ow timers, 112 preheating, 333 pressure controlled welding, 333 pressure welding, 333 preweld intervals, 333 projection welding, 333 projects campfi re grill, 249–256 portable welding table, 242–248 torch cart, 231–242 propane, gas welding and, 187 protective clothing, 38–39 puddles, 94, 333 pulsation welding, 334 pulse transfer, 137 push feeders, 141 push welding, 334 push-pull feeders, 141 • Q • quenching, 196, 334 • R • reaction stress, 334 reader assumptions, this book, 3 regulators acetylene, 192, 194 defined, 334 gas welding, 190, 191 gauge, standing away from, 191 oxyfuel cutting, 168, 171 oxygen, 191 plasma arc cutting, 174 reinforced welds, 334 repairs. See also piece failure aluminum, 262, 264 base metal condition, 265 base metal strength, 265 cast iron, 262, 264 compromise of other pieces and, 259 copper, 262, 264 cost versus new piece, 258–259 cracks and, 269–271 defined, 10 determination if fixable, 258–259 electrodes for, 267, 268–269 equipment and tools for, 267–268 equipment failure and, 258 fi ller rods for, 267, 269 fi rst step for, 258Index 355 hardfacing, 263 joints, 265–266 magnetism check, 261 metal color identifi cation chart for, 260–261 metal identification, 260–262 metal identifi cation kit and, 261 piece preparation, 266–267 plan, making/following, 265–266 skill level for, 265 spark test, 261 strategy, planning, 259–266 time for, 264 weld aesthetic, 264 weld preparation, 266–269 weld strength, 259 welding process decision, 264–265 as welding use, 10–11 work area preparation, 266–267 residual stress, 334 resistance butt welding, 334 resistance to oxidation, 22 resistance welding, 334 respirators filters, 40 illustrated, 40 for repairs, 268 in stick welding, 82 types of, 39 right-handed fi ttings, gas cylinders, 188 robotic mig welding, 137 Rockwell hardness test, 334 root edge, 335 root face, 335 root pass, 210–211, 213, 335 • S • safety. See also injuries burns, 46–47, 50–52 cleaning, 25 electric shock, 45–46 equipment, 47–48 fi rst-aid kit, 48–49 fl ammable liquids/gases and, 43–44 gear, 34–40 importance of, 14 leaks, 42 oxyfuel cutting, 179 precautions, talking, 33 rules, 40–48 smells and sounds, 45 soldering, 201 surroundings, 44–45 tips, 41 ventilation, 42–43 work space, 41 sandblasting, 335 SAW (submerged arc welding), 338 sawhorses, steel, 278–280 scaling, 13 scarf, 335 scarfing, 335 Schedule 40 pipe, 207 scrap metal safety, 45 scratching method, stick welding, 95 screwdrivers, 308 seal welds, 335 seam welding, 335 selective block sequence, 335 series welding, 335 shade number, 35 sheet metal, mig welding on, 155 sheet separation, 335 shielded metal arc welding (SMAW). See stick welding shielding gases (mig welding) argon/argon mixes, 142 carbon dioxide, 142 cast iron, 227 defined, 336 fl ow rate, 149 helium/helium mixes, 142 suggestions, 143 supply chamber installation, 148 shielding gases (tig welding) argon, 114–115 cylinders, 112 defi ned, 106, 109, 336 fl ow meters, 113, 122 fl ow rate, 113 helium, 114 hook up, checking, 122 selecting and managing, 112–115 setting up, 122–123 solenoid and, 122–123356 Welding For Dummies shirts, 38 shoes, 38 shop welds, 336 short circuit transfer, 136, 150 sidebars, this book, 2 single impulse welding, 336 slag defined, 336 not sticking to weld, 302 in pipe welding, 208 in stick welding, 15 slag inclusions. See also defects causes, 295 defi ned, 294, 336 illustrated, 295 slot welds, 336 slugging, 336 SMAW (shielded metal arc welding). See stick welding soapstones circles, 176, 183 defi ned, 59, 96, 175 in oxyfuel cutting, 181, 183 in plasma arc cutting, 175, 176 as repair tool, 267 sharpening, 83 straight lines, 175, 181 in torch cart project, 241 uses, 59, 83 socket joints, 214 soft arc electrodes, 88 solder applying, 203 cooling/hardening, 201 correct, using, 201 defined, 199 lead-free, 201, 202 rosin core, 201, 202 soldering cleanup after, 203 defi ned, 18, 199, 336 drawbacks, 199, 200 flux, 201 fl ux inclusions, 295 with gas torch, 202, 203 heat application, 201 joint fit, 200 joint illustration, 200 joint strength, 199 materials, 201 materials illustration, 202 metal cleanliness, 200 process, 202–203 rules, 200–201 safety, 201 soft, 201 with soldering iron, 202, 203 torch, 201, 202 types, 202 uses, 199 solenoids, 122–123 spacer strips, 336 spall, 336 spark test, 220, 261 spats, 39 spatter defi ned, 299, 336 illustrated, 152 minimizing, 299 in pipe welding, 208 in stick welding, 15 speed of travel as incomplete penetration cause, 292 stick welding, 75, 95 weld size control with, 301 spool guns, 141 spot welding, 336–337 spray arc transfer, 136–137, 150–151, 337 stainless steel. See also metals butt joint, 130 characteristics, 13 color test, 260 400 series, 27 lap joint, 131 mig welding, 28 steel versus, 27 stick welding, 28 T joint, 132 tig welding, 28, 108, 125 200 to 300 series, 27 use decision, 27–28 welding methods, 28 working with, 27–28Index 357 steel. See also metals bars, 20 butt joint, 130 carbon, 13 characteristics, 13 cleaning, with chemicals, 25 cleaning, with mechanical methods, 23–25 cold rolled, 21 color test, 260 decision to use, 21–22 defined, 20 flat, 20 forms, 20–21 heat treating, 337 high carbon, 20 hot rolled, 21 information resource, 22 lap joint, 131 low carbon (mild), 20 medium carbon, 20 mig welding, 26, 150–151 preparing for welding, 23–25 stainless steel versus, 27 stick welding, 26 T joint, 132 tig welding, 26, 109, 124 weathered, 23 welding methods, 26 steel pieces campfi re grill project, 250–251 portable welding table, 243–244 steel pieces, cutting, 251–253 torch cart project, 233–234 steel pipes. See also pipe welding high pressure, 206 low pressure, 206 medium pressure, 206 with stick welding, 205, 206 welding, 206–215 steel sawhorses, 278–280 steel squares, 59, 60 stick welding advantages, 74 aluminum, 30 arc length, 75, 94, 319 arcs, striking and maintaining, 93–95 combination square, 83 coveralls, 81 defi ned, 15, 337 drawbacks, 15–16, 74–75 electrode holder, 82, 92, 325 equipment, 76–83 factors influencing, 75–76 fl at surface, 96–97 gloves, 82 ground clamps, 82 horizontal, 101–102 how it works, 16 injuries, 87 overhead, 102–104 in pipe welding, 205, 206 popularity, 15, 64 positions, 95–104 preparation, 86–90, 92–93 respirator, 82 slowness, 75 soapstones, 83 speed of travel, 75, 95 stainless steel, 28 steel, 26 success factors, 94–95 tig welding machines for, 111 tools and supplies, 81–83 vertical, 97–100 welding cables, 83 welding helmet, 81 work area setup, 86–87 working with, 85–104 stick welding (cast iron) components for, 222 cracked cast iron, 221, 223 drill/drill bit, 222 electrodes, 222 grinder, 222 illustrated, 224 oxyacetylene torch, 222 process, 223–224 temperature indicating crayon, 223 stick welding electrodes amperage, setting, 90, 91–92 angle, 75, 94 arc blow, 81358 Welding For Dummies stick welding electrodes (continued) burning too fast on one side, 81 for cast iron, 222 characteristics, 87–88 classifications, 89–90 covered, 93 defined, 87 exposure to moisture/air, 89 fast fi ll and fast freeze, 268 in fl at surface welding, 97 fl ux, 16, 93 handling, 80 iron powder, 88 keeping dry, 80 material matching, 88 7018 and 7028, 268–269 6010 and 6011, 268 sizes, 88 soft arc designation, 88 storage oven, 90 strength, 88 stubs, 75 types of, 87 understanding, 87–90 in vertical-down welding, 100 wasting, 74 welding positions and, 88 stick welding machines. See also welding machines AC versus DC, 64, 76–77 in cast iron welding, 223 defined, 64 differences, 76–80 duty cycle, 77 generators, 77, 78 illustrated, 65 inspecting, 90 inverter, 79 maintenance, 311–312 output rating, 77 polarity, 64, 76–77 power source, 77–79 setting, 90–93 setting up, 79–80 transformer, 77, 78, 341 stitch welds, 337 storage, 67 stored energy welding, 337 straight lines oxyfuel cutting, 181–182 plasma arc cutting, 173–176 straightedges, 59, 60 strength base metal, 265 defi ned, 12, 22 repair weld, 259 requirements, weld meeting, 305 tensile, 88, 218, 338 yield, 219 striking an arc (stick welding) defined, 93–94 scratching method, 95 success factors and, 94–95 tapping method, 95 striking the arc (tig welding) with DC, 127 preparation, 126 remote control device, 126–127 scratch starting, 126 string bead welding, 337 stud welding, 338 submerged arc welding (SAW), 338 subsurface cracks, 269 sugar, 338 • T • T joints. See also joints defined, 131 illustrated, 132 lateral, 214 pipe welding, 214 tig welding process, 132 tack welding campfi re grill, 253 defi ned, 99, 338 portable welding cart, 244 torch cart project, 236–237 tape measures, 59, 267, 307 tapping method, stick welding, 95 temper colors, 338 temperature indicating crayon, 223Index 359 tempering, 338 tensile strength, 88, 218, 338 tension test, 338 thermit mixture, 339 thermit mold, 339 thermit reaction, 339 thermit welding, 339 thick plates, 270 thoriated electrodes, 117 thoriated tungsten, 339 3/8-inch electric drills, 277–278 throat depth, 339 tig torches defined, 112 holding, 127 illustrated, 113 striking the arc, 126–127 using, 125–127 tig welding advantages, 17, 106–107 aluminum, 30, 125 amperage control, 115 butt joints, 129–130 characteristics, 105 components, 106 current control, 115 defi ned, 17, 339 disadvantages, 107 drawbacks, 17 electrical current selection, 125–126 equipment, 110–117 fi ller metal, 116–117 fi ller rods for, 116 fi rst weld, 128–129 how it works, 17 lap joints, 130–131 metals for, 108–109 practicing, 119–132 quality welds, 109 setting up for, 119–123 setup, 110 shielding gas, 106, 109, 112–115, 122–123 stainless steel, 28, 125 steel, 26, 124 striking the arc, 126–127 T joints, 131–132 wind and, 114 tig welding machines defined, 66 features and controls, 111–112 fully equipped, 111–112 illustrated, 67, 114 maintenance, 314–315 polarity, 66 starting modes, 111 for stick welding, 111 timers, 112 tig welding tungsten electrodes, 106, 112 breaking, 121 contamination, 121–122 diameters, 117 green, 117 grinding, 121 as non-consumable, 120 red, 117 shaping tip of, 117 thorium alloy, 117 types and applications, 120–121 toe, weld, 339 toolboxes illustrated, 283 sizes, 283 as top tool, 282 tools, most wanted air compressor, 277 bench grinder, 281–282 bottle jack, 282 cutoff saw, 280–281 4 1/2-inch grinder, 276 hacksaw, 276 steel sawhorses, 278–280 3/8-inch electric drill, 277–278 toolbox, 282–283 wrench set, 278 torch cart. See also projects angle irons, 237–238 base and handle welds, 237–238 base pieces, 234 benefits, 231 box, 238–240 box pieces, 234 creating, 231–242 design, 232 distortion, 236360 Welding For Dummies torch cart (continued) gas cylinders, 232 illustrated, 232 materials, 233 paint, 242 partially welded, 239 pieces, cutting, 236 pieces, measuring, 235–236 steel pieces, 233–234 steel pieces illustration, 235 tack welding, 236 welds, 236–240 welds, checking, 241 wheels, 234, 240–241 torches brazing, 196, 197 defi ned, 323, 341 fusion welding, 198 gas, 187, 189, 191–193 oxyfuel, 168, 179–181 plasma cutting, 163–164, 175, 176, 177–178 soldering, 201, 202 tig, 112–113, 125–127 transformers, stick welding machines, 77, 78, 341 traverse seam welding, 339 tungsten electrodes. See tig welding tungsten electrodes 2G vertical fi xed position open root pipe weld, 213 • U • ultrasonic testing, 339 underbead cracks, 340 undercutting. See also defects causes, 294 defi ned, 211, 293, 340 illustrated, 294 no, as sign of good weld, 304 in pipe welding, 211 underfill, 304 upset welding, 340 used welding machines, 63–64 • V • ventilation importance, 43 need for, 42–43 for repairs, 268 in welding shop location selection, 54 vertical stick welding types of, 97–98 vertical-down, 98, 100 vertical-up, 98–99 vertical welding defined, 340 mig welding, 154 pipe welding, 213 vise grips, 59, 308 vises, 69 voltage, for mig welds, 145, 150–151 V-shaped grooves, 222, 292 • W • wall clocks, 69 wandering block sequence, 340 wandering sequence, 340 warpage, 298 weathered steel, 23 weaving, 340 weld gauge, 341 weld metal, 341 weldability, 341 welding. See also mig welding; stick welding; tig welding braze, 195–197 cast iron, 221–228 defined, 10 fusion, 197–199 future of, 18 gas, 187–194 history, 11 importance of, 10 methods, 15–18 oxyfuel/oxyacetylene, 18 pipe, 205–215Index 361 safety, 14, 33–52 technique, 341 uses, 10–11 welding cables, 83 welding curtains, 69 welding educators, 287 welding engineers, 287 welding helmets. See helmets, welding welding inspectors, 287 welding machines carriage, 68 current, 62 defined, 62 duty cycle, 62, 77 material type/size and, 63 mig, 65–66 new, 63 plasma arc cutting, 161, 163–164 power source, 62 for repairs, 267 stick, 64–65, 76–80 tig, 66–67, 111–112 used, 63–64 welding pressure, 341 welding procedure qualification record (WPQR), 215 welding procedure specifi cations (WPS), 215 welding shops accessories, 67–69 doors, 54 electrical service, 54 equipment, 56–69 fl ame retardant fl oors and walls, 54 housekeeping, 310 indoor versus outdoor, 55–56 lighting, 54 location selection, 53–56 setting up, 53–69 space needs, 54–55 storage, 67 ventilation, 54 welding supervisors, 287 welding symbols, 341 welding tables, 61–62 welding technicians, 287 welding torches. See torches welding transformer, 77, 78, 341 weldment, 341 welds axis of, 320 back, 320 backing, 227, 320 bead, 320 butt, 321 butter, 321 campfi re grill, 253, 254 chain intermittent fillet, 322 cold, 322 defined, 340 distributed equally between parts, 301–302 effective length of, 325 face of, 325 field, 325fi llet, 326 full fillet, 326 full penetration, 304 fusion welding, 199 gas welding, 194 good, signs of, 301–305 groove, 327 horizontal, 328 leakproof, 303 loose, 303 no overlap, 304 no undercutting, 304 plug, 332 portable welding cart, 244 reinforced, 334 root of, 335 seal, 335 shop, 336 size control, 301 slag/shielding material not sticking to, 302 slot, 336 staggered intermittent fillet, 337 stitch, 337 strength requirements and, 305 surface, no irregularities on, 302 tight, 303 toe of, 339362 Welding For Dummies welds (mig welding) beads, 152, 153 depth, 139 excessive penetration, 156 feed speed setting, 145, 150 incomplete fusion, 156 incomplete penetration, 156 tack, 154 vertical, 154 voltage setting, 145 whiskers, 156 welds (pipe welding) location, 210 1G horizontal rolled open root, 212 penetration, 208 tack, 209, 210 2G vertical fi xed position open root, 213 welds (repair) aesthetic, 264 cast iron, 263 strength, 259 welds (stick welding) goal, 95 illustrated examples, 96 width, 75 welds (tig welding) autogenous, 116 butt joint, 129–130 first, 128–129 lap joint, 130–131 porosity, 109 quality, 109–110 stainless steel, cracking, 108 T joints, 131–132 variables affecting, 111 welds (torch cart project) base and handle, 237–238 box, 238–240 checking, 241 finalizing, 238–240 grinding, 241 making, 236–240 tack, 236–237 wire brush on, 241 wheels portable welding table project, 244, 248 torch cart project, 234, 240–241 whiskers, 156 wire brushes, 60, 308 wire feed speed, for mig welds, 145, 150– 151, 341 work space cleaning, 41 stick welding, setting up, 86–87 WPQR (welding procedure qualification record), 215 WPS (welding procedure specifications), 215 wrenches box-end, 278 crescent, 58, 60 maintenance, 308 open-end, 278 sets, 278, 279 wrought iron, color test, 260 • Y • Y joints, lateral, 214 yield point, 341Apple & Macs iPad For Dummies 978-0-470-58027-1 iPhone For Dummies, 4th Edition 978-0-470-87870-5 MacBook For Dummies, 3rd Edition 978-0-470-76918-8 Mac OS X Snow Leopard For Dummies 978-0-470-43543-4 Business Bookkeeping For Dummies 978-0-7645-9848-7 Job Interviews For Dummies, 3rd Edition 978-0-470-17748-8 Resumes For Dummies, 5th Edition 978-0-470-08037-5 Starting an Online Business For Dummies, 6th Edition 978-0-470-60210-2 Stock Investing For Dummies, 3rd Edition 978-0-470-40114-9 Successful Time Management For Dummies 978-0-470-29034-7 Computer Hardware BlackBerry For Dummies, 4th Edition 978-0-470-60700-8 Computers For Seniors For Dummies, 2nd Edition 978-0-470-53483-0 PCs For Dummies, Windows 7 Edition 978-0-470-46542-4 Laptops For Dummies, 4th Edition 978-0-470-57829-2 Cooking & Entertaining Cooking Basics For Dummies, 3rd Edition 978-0-7645-7206-7 Wine For Dummies, 4th Edition 978-0-470-04579-4 Diet & Nutrition Dieting For Dummies, 2nd Edition 978-0-7645-4149-0 Nutrition For Dummies, 4th Edition 978-0-471-79868-2 Weight Training For Dummies, 3rd Edition 978-0-471-76845-6 Digital Photography Digital SLR Cameras & Photography For Dummies, 3rd Edition 978-0-470-46606-3 Photoshop Elements 8 For Dummies 978-0-470-52967-6 Gardening Gardening Basics For Dummies 978-0-470-03749-2 Organic Gardening For Dummies, 2nd Edition 978-0-470-43067-5 Green/Sustainable Raising Chickens For Dummies 978-0-470-46544-8 Green Cleaning For Dummies 978-0-470-39106-8 Health Diabetes For Dummies, 3rd Edition 978-0-470-27086-8 Food Allergies For Dummies 978-0-470-09584-3 Living Gluten-Free For Dummies, 2nd Edition 978-0-470-58589-4 Hobbies/General Chess For Dummies, 2nd Edition 978-0-7645-8404-6 Drawing Cartoons & Comics For Dummies 978-0-470-42683-8 Knitting For Dummies, 2nd Edition 978-0-470-28747-7 Organizing For Dummies 978-0-7645-5300-4 Su Doku For Dummies 978-0-470-01892-7 Home Improvement Home Maintenance For Dummies, 2nd Edition 978-0-470-43063-7 Home Theater For Dummies, 3rd Edition 978-0-470-41189-6 Living the Country Lifestyle All-in-One For Dummies 978-0-470-43061-3 Solar Power Your Home For Dummies, 2nd Edition 978-0-470-59678-4 Available wherever books are sold. 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