كتاب Welding Basics - An Introduction to Practical & Ornamental Welding
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 كتاب Welding Basics - An Introduction to Practical & Ornamental Welding

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Welding Basics - An Introduction to Practical & Ornamental Welding

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Contents
Introduction
Introduction to Welding
Safety
Setting Up Shop
Shop Tools
Metal Basics
Welding & Cutting Processes
Oxyacetylene Welding
Electricity for Welding
Shielded Metal Arc Welding
Gas Metal Arc Welding
Gas Tungsten Arc Welding
Plasma Cutting
Oxyacetylene Cutting
Welding Projects
Shop Projects
Rolling Welding Curtain
Welding Table
Welding Machine Cart
Cylinder Cart
Grinder Stand
Lighting Projects
Scroll Desk Lamp
Three Post Floor Lamp
Chandelier
Wall-mounted Candleholder
Tree-shaped Candleholder
Fireplace Candleholder
Furniture Projects
Baker’s Shelves
Coffee TableCorner Coatrack
Kitchen Appliance Stand
Wall Hung Plate Rack
Wine Rack
Headboard
Outdoor Projects
Stair Railing
Gate
Critter Boot Brush
Disk Fountain
Arbor
Glossary
Resources
Index
INDEX
Acetylene, 27, 35
See also: Oxyacetylene cutting, Oxyacetylene welding
Air compressors, 64, 65, 66
Alloys, 15, 22, 57, 62
Aluminum, 15
preparing, 18
repairing, 22, 23
Amperage, 38–39, 42, 43, 65
Angle iron, 16
Arbor, 134–137
Arc welding,
electricity, 38–39
preparing for, 23
See also: Flux cored arc welding,
Gas metal arc welding, Gas tungsten
arc welding, Shielded metal arc
welding
Arcs, 38, 64, 66
burn, 10
striking, 60
Artwork, 4, 5, 6, 7, 36
Auto-darkening lenses, 11, 54
See also: Helmets
Backfire, 31
Backseating valve, see: Cylinders
Baker’s shelves, 106–109
Base metals,
identifying, 22
matching electrode size, 8, 23
matching filler material, 8, 23
matching welding process, 9
See also: Metals
Bird’s nests, 53
Blowpipes, see: Torches Boot brush, 130–131
Brakes, 19
Braze welding, 14, 37
Brazing, 11, 14, 35, 36
Burns, 10, 68
Burn through, 8, 34
Butt joint, 20Candelabra, 5
Candleholders,
chandelier, 96–97
fireplace, 102–103
tree-shaped, 100–101
wall-mounted, 98–99
Carburizing flames, 33
Carts, see: Cylinders, Welding machines
Cast aluminum, see: Aluminum
Cast iron, repairing, 23
Chandelier, 96–97
Channel, 16
Chemical sharpeners, 57, 58
Circle cutting, 67, 71
Clothing, protective, 10, 11, 27, 41, 45, 54, 55, 65, 68, 69
Coatrack, 112–113
Coffee table, 110–111
Collet and collet body, see: Torches
Concrete, risk of explosion, 11
Corner joint, 20
Corrosion, 9, 15
Costs, 5, 17, 26, 65, 67, 68, 69
Cutouts, making, 71
Cutting processes, 14, 38–39
See also: Oxyacetylene cutting,
Plasma cutting
Cylinders,
cart, 85–87
gas metal arc welding, 44, 47, 49
gas tungsten arc welding, 54, 55, 61
oxyacetylene cutting, 68
oxyacetylene welding, 26, 30
risk of explosion, 11, 28, 65
safety, 27, 47, 68, 71
valves, 27, 29, 31, 32, 49
wrenches, 30, 31
Decorative metal products, 17, 94–95, 102–103, 110–111, 114–115, 118–119, 120–121, 124–127
Duty cycles, 39, 65
Edge joint, 20
Electrical shocks, 11, 12, 40, 65
Electricity, 38–39, 41, 55, 59, 64
Electrodes, 8, 23, 40, 42, 44, 46, 50, 52, 54, 55, 58, 65characteristics, 57
holders, 40, 41, 43
leads, 41, 43
stub out or stubbing, 53
tungsten, 56, 57
Equipment, see: Air compressors,
Cylinders, Electrodes, Fillers, Fire bricks, Fittings, Flashback arrestors, Flow meters, Foot control, Gases,
Gauges, Guns, Hoses, Power supply, Regulators, Supply cables, Tips, Tools, Torches, Welding machines,
Wire feed, Work cables/leads and clamps
Explosions, risk of, 11, 28, 65
FCAW, see: Flux cored arc welding
Ferrous metals, 14
Fillers, 8, 15, 23, 34, 42
braze welding, 37
brazing, 36
gas metal arc welding, 44
gas tungsten arc welding, 54, 58, 60–61, 62
oxyacetylene welding, 26
Fillet weld, 20, 21, 37, 63
Filters, 10, 11, 27, 41, 45, 55, 65, 69
See also: Shades, Shields Finishes, 18
Fire bricks, 11, 27, 34, 35, 37
Fire extinguishers, 10, 71
Fires, risk of, 10, 12, 68
Fishmouth joint, 20
Fittings, oxyacetylene, 28
Flame cutting, see: Oxyacetylene cutting
Flames, 32, 33, 70
Flange joint, 20
Flashback, 28, 31
arrestors, 29
Flat bar, 16
Flow meters, 47, 49, 50, 51, 55, 56, 61
Flux, 9, 36, 37, 42, 45
Flux cored arc welding, 9, 47, 51
Foot control, 54, 55, 60
Fountain, 132–133
Fuel gases, see: Gases
Fumes, 10, 12, 41, 64
Furniture projects, 104–121
Fusion welding, 26, 34
Gas leaks, 30, 31
Gas metal arc welding, 8, 9, 53electricity, 38–39
equipment, 44, 45–47, 52
maintenance, 52–53
safety, 47
shades/lenses, 11, 45
troubleshooting, 52–53
See also: Flux cored arc welding
Gas tungsten arc welding, 9, 54–63
electricity, 38–39, 59, 60
equipment, 54, 55–56, 59
preparing the electrode, 56–58
safety, 54, 55
shades/lenses, 11, 54
troubleshooting, 62–63
Gas welding, see: Oxyacetylene welding
Gases,
fuel, 26, 35, 69
shielding, 42, 44, 45, 46, 47, 49, 50, 51, 54, 55, 56, 61
Gates, 7, 129
Gauges, 30, 31
Gauge thickness, inch equivalents, 17
Glasses, safety, 11
GMAW, see: Gas metal arc welding Grinder stand, 88–89
Groove weld, 20, 21, 37
Ground leads and clamps, see: Work cables/leads and clamps
GTAW, see: Gas tungsten arc welding
Guns, 44, 45, 48, 50, 51, 52
spool, 46
Hard soldering, 36
Headboard, 120–121
Heat distortion, 8
Heat-treated metals, 15, 22
Heliarc, see: Gas tungsten arc welding, 54
Helmets, 11, 27, 41, 45, 55, 65
auto-darkening lenses, 11, 54
See also: Filters, Shades, Shields Hexagonal bar, 16
High-carbon steel, 15
Holes, piercing, 71
Hooks, making, 113
Hoses,
gas metal arc welding, 47, 49, 50, 52
gas tungsten arc welding, 61
oxyacetylene cutting, 68, 70oxyacetylene welding, 26, 28, 29, 30, 34, 35
Infrared light, safety, 10, 41
Innershield, see: Flux cored arc welding
Insurance, 12
Jigs, 19, 108, 109, 115, 117
Joints, 20
Kerf, 64, 71
Kitchen appliance stand, 114–115
Lamps, 92–93, 94–95
Lap joint, 20
Lighting projects, 90–103
Melting points, 15
Metal inert gas (MIG), see: Gas metal arc welding
Metals, 14–23
braze welding, 37
brazing, 36
cutability, 14, 19
finishing, 18
heat-treated, 15
measuring, 16–17
melting points, 15
painting, 18
preheating, 23, 69, 71
preparing, 18, 22, 34
purchasing, 17, 79, 88, 92, 125, 132–133, 140
repairing, 22–23
shapes, 16
shaping, 19, 93, 97, 108, 109, 117
sizes, 16
types, 14–15
weldability, 14
See also: Decorative metal products,
Fillers
Metalworking tools, 19, 107, 108, 109, 117
MIG, see: Gas metal arc welding MIG pliers, 45, 52
Mild steel, 14, 16
preparing, 18
repairing, 22
Mill scale, 18, 34
Molten puddle, 8, 9, 58, 60Neutral flames, 33, 35, 70
Non-ferrous metals, 14
Nozzles, see: Tips
Outdoor projects, 122–137
Oxidizing flames, 33
Oxyacetylene cutting, 9, 68–71
equipment, 68–69
pressuring the system, 30, 31, 70
safety, 7, 68, 69, 71
setting up, 30, 70
shades/lenses, 11, 69
tools, 69, 71
Oxyacetylene welding, 8, 26–37
depressurizing the system, 35
equipment, 26–29
leaks, 30, 31
pressuring the system, 30, 31, 34
safety, 27, 28, 29, 31, 32
setting up, 30
shades/lenses, 11, 27
tools, 27
Oxyfuel brazing, see: Brazing
Oxyfuel cutting, see: Oxyacetylene cutting
Oxyfuel welding, 26
See also: Oxyacetylene welding
Oxyfuels, 26, 35
Oxygen, 9
Particle masks, 10, 11
Penetration of the weld, 8, 22
Pipe, 16
Plant stand, 7, 114
Plasma cutting, 9, 64–67
electricity, 38–39
safety, 11, 64–65
shades/lenses, 11, 65
troubleshooting, 67
Plate metal, 16
Plate rack, 116–117
Power supply, 39, 40, 44, 45, 51, 54, 64
Preheating metals, 23, 69, 71
Pressure regulators, see: Regulators
Puddle, see: Molten puddlePurchasing metal, 17, 79, 88, 92, 125, 132–133, 140
Racks,
corner, 112–113
plate, 116–117
wine, 118–119
Rail cap, 16, 125
Railing, see: Stair railing
Rectangular tube, 16
Reducing flames, 33
Regulators,
gas metal arc welding, 44, 47, 50
gas tungsten arc welding, 54, 55
oxyacetylene cutting, 68, 69
oxyacetylene welding, 26, 28, 30, 31, 32, 35
Repairing metal, 22–23
Resources, 140
Respirators, 10, 11
Round bar, 16
Round tube, 16
Rust, 9, 15, 34
Saddle joint, 20
Safety, 7, 9, 10–11, 12, 22, 27, 28, 29, 31, 32, 40, 41, 47, 54, 55, 64–65, 68, 69, 71, 125, 128
Scratch starts, 60
See also: Arcs
Scrolls, making, 92–93, 96–97, 102, 107–109, 116–117
Shades, 11
See also: Filters, Shields
Sheet metal, 16, 17
Shelves,
baker’s shelves, 107–109
corner coatrack, 112–113
kitchen appliance stand, 114–115
Shielded metal arc welding, 8, 9, 43
electricity, 38–39
equipment, 40, 41–42
safety, 40–41
shades/lenses, 11, 41
Shielding gases, 9, 12, 42, 44, 45, 46, 47, 49, 50, 51, 54, 55, 56, 61
Shields, for helmets, 11, 27
See also: Filters, Shades
Shocks, see: Electrical shocks
Shops, welding,
projects, 74–89safety, 12, 40
See also: Costs
Slag, 9, 40, 42, 43, 47, 51, 70, 71, 79
burns, 10, 68
risk of fire, 12, 68
SMAW, see: Shielded metal arc welding
Smoke, 10, 58, 64
Soldering, see: Brazing
Spark lighter, 27, 32, 69, 70
Sparks, 64, 68, 71, 79
burns 10
risk of fire, 12
Spatter, 41, 47, 50, 52
Square bar, 16
Square tube, 16
Stainless steel, repairing, 23
Stair railing, 125–127
Stands,
grinder stand, 88–89
kitchen appliance, 114–115
See also: Tables
Starter cartridge, see: Plasma cutting
Stick welding, see: Shielded metal arc
welding
Strap, see: Flat bar
Stub out or stubbing, 53
Suppliers, 17, 140
Supply cables, 44, 45, 50, 51, 52, 55, 64
Tables, see: Coffee table, Welding table
See also: Stands
Tanks, see: Cylinders
T-bar, 16
Temperature crayons, 23
TIG, see: Gas tungsten arc welding
Tip cleaner, 27, 69, 71
Tips,
cutting head, 28, 29, 65, 70
gas metal arc welding, 46, 50–51, 52
matching to material or process, 29, 31, 34
oxyacetylene cutting, 68, 69, 70, 71
oxyacetylene welding, 26, 28, 29
rosebud heating, 28, 29
T-joint, 20Tools, 13, 97, 99, 101, 119
gas metal arc welding, 45
gas tungsten arc welding, 55, 57
metalworking, 19, 107, 108, 109, 117
oxyacetylene cutting, 69, 71
oxyacetylene welding, 27
plasma cutting, 65
shielded metal arc welding, 41
Torches,
flames, 32, 33, 70
gas tungsten arc welding, 54, 55
lighting, 32
oxyacetylene cutting, 68, 69, 70
oxyacetylene welding, 26, 29, 31, 32
plasma cutting, 64, 65
valves, 32
See also: Guns, Tips
Tungsten inert gas (TIG), see: Gas tungsten arc welding
Ultraviolet light, safety, 10, 41, 54, 65
Valves, see: Cylinders, Torches
Ventilation, 10, 12, 27, 41, 43, 45, 55, 64, 65, 66, 69, 70
Voltage, 8, 39, 50–51, 65
Wattage, 38–39
Welding curtain, rolling, 76–77
Welding machines, 40, 41, 43, 44, 45, 46, 47, 49, 52, 53, 55, 59
cart, 82–83
Welding processes, 14
See also: Flux cored arc welding,
Gas metal arc welding, Gas tungsten
arc welding, Oxyacetylene welding,
Shielded metal arc welding
Welding table, 79–81
Welding tarp, see: Welding curtain
Welds,
fillet weld, 20, 21
groove weld, 20, 21
symbols, 21
troubleshooting, 62–63
Wine rack, 118–119
Wire brushing, 18, 23, 34, 41
Wire feed, 44, 45, 46, 51, 53bird’s nests, 53
setting up, 48
Wire speed, 8, 45, 48, 50–51
Wire spools, 46
Wires,
tangles, see: Bird’s nests
See also: Electrodes
Work cables/leads and clamps, 39, 40, 41, 43, 44, 46, 50, 51, 52, 54, 55, 61, 64, 66
Zigzag trim, 106–109© Copyright 2004
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