Beginner Tips and Tricks
A collection of practical shop tips designed to help welders improve technique, efficiency, weld quality, and equipment longevity.
Post-Weld Cleanup
Chip off the slag with a welding hammer and use a 36-grit grinding wheel to knock the beads down to the surrounding metal. To ensure a flat, flush surface, move the grinder along the length of the weld, not across it.
Joining Metal by Brazing
Brazing galvanized sheet metal can be accomplished using a MIG welder with bronze wire and argon. It works great for sealing up the corners of a box, and it flows right into the zinc for a nice, neat fillet.
The use of adequate ventilation and an approved respirator is necessary to avoid overexposure to zinc — which can cause metal fume fever — from galvanized metal being welded.
Use Arc Length and Electrode Angle to Your Advantage
– MICHAEL PAUL, BRENTWOOD, TENNESSEE
The arc length and angle of the electrode are important in producing quality welds. Excessive arc length can produce excessive weld spatter and arc blow, while insufficient arc length can cause the electrode to sputter or stick. Arc length can be used to control the heat input in the weld area. A shorter arc length will reduce heat input and a longer arc length will raise the heat input in the weld area. The angle of the electrode has similar effects on the weld area. Too much angle will increase heat input within the weld area that may cause spatter and arc blow. Too little angle lowers the heat input and can cause the electrode to sputter or stick.
Don't Hold Back on the Preparation
For a great weld every time, no matter where or when, preparation is critical. The key to a clean, sound weld is to make sure your welding surface is as clean as possible. If there are any contaminants or other metal coating/protection on your weld surface, use a compound made for cleaning weld surfaces or grind the surface. Get right down to the bare metal to ensure you have a clean, bare surface to start making great-looking welds.
Be sure to wear the appropriate personal protective equipment, such as gloves and eye protection, when grinding.
Add More Life to the Lead Wire
To protect your lead wire at the stinger, mark the wire on your whip line. Then wrap six to eight layers of electrical tape 2 inches on either side of the mark. You'll wear out the tape instead of the wire's insulation. This will add life to the whip and save money.