Top welding tips: how to become a more skilled welder and how to select the top welding equipment. Contact tips can have a significant impact on MIG welding performance since this consumable is responsible for transferring the welding current to the wire as it passes through the bore, creating the arc. The position of the contact tip within the nozzle, referred to as the contact tip recess, is just as important. The correct contact recess position can reduce excessive spatter, porosity, insufficient penetration, and burn-through or warping on thinner materials. While the ideal contact tip recess position varies according to the application, a general rule of thumb is that as the current increases, the recess should also increase.

Delivery of parts to the welding station in an organized and logical fashion is also a way to reduce welding costs. For example, one company was manufacturing concrete mixing drums. In the fabrication process, the company produced 10 parts for one section, then went on to make 10 parts of another drum section, etc. As pieces came off the line, they were put onto the floor of the shop. When it was time to weld, the operator had to hunt for the pieces needed and sort through them. When the outside welding expert pointed out the amount of time being wasted in this process, the company started to batch each one on a cart. In this way, the pieces needed to weld one drum were stored together and could easily be moved to the welding area. This type of scenario is also true for companies that may outsource parts to a vendor. Though it may cost more to have parts delivered in batches, it may save more in time than having to organize and search through parts to be able to get to the welding stage. How many times each piece is handled in the shop may be an eye-opener to reducing wasted time. To measure such an intangible as this, operators are asked to put a soapstone mark on the piece each time it is touched – some companies are surprised to find out how many times a part is picked up, transported and laid down in the manufacturing process. In the case of one company, moving the welding shop closer to the heat treatment station eliminated four extra times that the part was handled. Basically, handling a part as few times as possible and creating a more efficient production line or work cell will reduce overall costs.

A few tips on welding equipment, MIG and TIG welders, plasma cutters. Identify the types of welding projects and materials you will weld most of the time. Are you creating metal sculptures? Do you intend to restore an old muscle car in your garage? Does the motorcycle you bought years ago require some fabrication? Maybe you need to do basic repair on farm equipment. Taking the time up front to identify the projects that will occupy the biggest percentage of your welding activity will help you determine the specific thickness of metal you will likely weld most often – and ultimately help you select the most suitable welder. Time to get a bit more specific. Let’s take a look at what welding process you can use for each metal type. Keep in mind that many of these materials are also processed using varying combinations of two or more metals to reinforce strength and functionality.

Flat-Position Welding Increases Welding Speed : It’s common knowledge that welding in a horizontal position will be the easiest and fastest way to weld. A flat position is not as taxing to maintain and the welding puddle will stay in place. Take some time to evaluate each project before beginning in order to make sure the majority of welds can be completed in this position. If a job calls for vertical welding, see this article about vertical welding. Core Wire Feeder Increases TIG Welding Speed: For professional welders hoping to speed up TIG welding, a core wire feeder will add filler metal through an automated process. Watch this video on how it works. This enables welders to work with both hands and to maintain a constant flow of wire into the welding puddle. Ed Craig at the Frabricator writes about the wire feeder process first developed in Europe, saying it is “suitable for all-position welding on materials of any thickness, the process addresses traditional GTAW limitations and can enhance both manual and automated TIG weld quality and productivity.” Find additional info on MIG welders.

Use gas lens style collet bodies and cups to weld stainless steel: Use gas lens style collet bodies and cups to weld stainless steel. The screen in the gas lens allows far better gas coverage of your welds. You can use gas lenses to weld all materials is you want; they also allow you to stick your tungsten up to 1” out of the cup by increasing gas flow. Sometimes you need to extend it just to reach a tight spot. The screen diffuses gas at higher gas flow rates eliminating turbulence which is what you would get if you tried this without the gas lens. Too much gas is as bad as too little gas. (Especially for TIG welding aluminum) Typical gas flow rates are around 15 to 20 cfh. Bu it really depends on the nozzle/cup diameter. While I am on the subject, what do the numbers on TIG cups mean? I am glad you asked… A #4 means 4/16″ or 1/4″ A #7 means 7/16″. In other words the number cup means how large the inside diameter in 1/16’s. When you use a #4 cup remember to adjust the argon flow to around 10cfh. And the bigger the cup inside diameter, the more gas flow….to an extent.