Welding For Dummies

Title Page
Copyright Page
Table of Contents
Introduction
About This Book
Conventions Used in This Book
What You’re Not to Read
Foolish Assumptions
How This Book Is Organized
Part 1: Understanding Welding Basics
Part 2: Welding on a Budget: Stick and Tig Welding
Part 3: Discovering Mig Welding
Part 4: Getting Fancy: Plasma Cutting, Oxyfuel Cutting, and Other Processes
Part 5: Putting Welding into Action with Projects and Repairs
Part 6: The Part of Tens
Icons Used in This Book
Where to Go from Here
Part 1 Understanding Welding Basics
Chapter 1 Diving Into the World of Welding
If You Can’t Beat ’Em, Join ’Em: Understanding Why Welding Matters
Fabricating metal products
Repairing metal pieces or products
Getting Familiar with Metals
Steel
Stainless steel
Aluminum
Taking the Time to Understand Welding Safety
Exploring Welding Methods
Stick welding
Mig welding
Tig welding
Other welding methods
Looking at the Future of Welding
Chapter 2 Considering Commonly Welded Metals
Steeling Yourself for Using Steel
Getting a handle on forms of steel
Knowing when steel is appropriate
Preparing steel for welding
Exploring steel welding methods
Going with Stainless Steel
Understanding the differences between steel and stainless steel
Deciding when to use stainless steel
Looking at stainless steel welding methods
Working with Aluminum
Perusing the properties of aluminum
Eyeing aluminum welding techniques
Considering Other Metals
Chapter 3 Setting Your Sights on Welding Safety
Gearing Up to Protect Yourself
Choosing eye protection
Keeping the right fire extinguisher on hand
Wearing protective clothing
Watching health hazards: Using a respirator and Material Safety Data Sheets
Observing Basic Safety Rules
Keeping your work space clean
Checking for leaks
Getting the ventilation right
Storing flammable liquids and gases
Knowing your surroundings
Protecting yourself from electric shock
Shielding yourself from burns
Maintaining your equipment
Being Prepared for Injuries and Accidents
Equipping your first-aid kit
Knowing how to handle injuries
Chapter 4 Setting Up Your Welding Shop
Choosing a Location
Deciding how much space you need
Contemplating indoor versus outdoor
Equipping Your Welding Shop
Making sure you have the basic hand tools
Choosing a welding table
Selecting your welding machine
Considering a few accessories for your welding shop
Part 2 Welding on a Budget: Stick and Tig Welding
Chapter 5 Getting on the Stick: Understanding Stick Welding
Looking at the Pros and Cons of Stick Welding
Understanding the Factors That Influence Stick Welding
Getting Familiar with Stick Welding Equipment
Discovering the differences among stick welding machines
Setting up your stick welding machine
Nailing down the basics of stick welding’s electrodes
Choosing tools and supplies every stick welder needs
Chapter 6 Getting to Work with Stick Welding
Preparing to Stick Weld
Setting up your work area
Understanding stick welding electrodes
Setting the Machine
Choosing polarity
Setting the amperage
Preparing to weld
Striking and Maintaining an Arc
Assume the Position: Stick Welding in All Positions
Welding on a flat surface
Going vertical
Exploring horizontal welding
Reaching overhead
Chapter 7 To Tig or Not To Tig: Understanding Tig Welding
Taking a Closer Look at Tig Welding Components
Considering the Advantages and Disadvantages of Tig Welding
Brushing Up on Tig Welding Basics
Showing your metal: Looking at a few metals for tig welding
Taking steps to ensure quality welds
Stocking the Shop: Examining Tig Welding Equipment
Considering fully equipped tig machines
Thinking about tig torches
Selecting and managing shielding gas
Controlling current and amperage
Selecting filler metal
Exploring tungsten electrodes
Chapter 8 Trying Out Tig Welding
Getting Your Welding Setup Tig-ether
Taking care of tungsten electrode details
Making sure your shielding gas is set up correctly
Figuring out your tig filler rods
Matching Materials and Settings
Getting a Handle on Using Your Tig Torch
Choosing an electrical current and striking the arc
Get a grip: Holding your tig torch correctly
Giving Tig Welding a Try
Tackling the first weld
Trying a butt joint
Welding a lap joint
Making a T joint
Part 3 Discovering Mig Welding
Chapter 9 Understanding the ABCs of Mig Welding
Understanding How Mig Welding Works
Considering Mig Welding’s Advantages and Limitations
Bringing Out the Big Guns (And Other Mig Welding Equipment)
Mig welding machines
Mig welding guns
Electrode wire feeders
Sifting Through Shielding Gases for Mig Welding
Taking a Look at Electrode Wire
Adjusting Mig Equipment to Suit Your Mig Welding Project
Chapter 10 Practicing Mig Welding
Preparing to Mig Weld
Getting the equipment ready
Setting the wire feed speed and voltage
Settings for flux-cored arc welding
Settings for aluminum MIG welding
Trying Out Mig Welding
Making vertical mig welds
Joining pieces of sheet metal
Watching Out for Common Mig Welding Defects
Part 4 Getting Fancy: Plasma Cutting, Oxyfuel Cutting, and Other Processes
Chapter 11 Examining Plasma and Oxyfuel Cutting
Understanding Plasma Arc Cutting
Identifying some good materials for plasma cutting
Taking a look at plasma cutting’s advantages and disadvantages
Perusing and Preparing Plasma Arc Cutting Equipment
Getting a handle on plasma cutting equipment
Setting the equipment up properly
Exploring Oxyfuel Cutting Basics
Considering what you can (and can’t) cut with oxyfuel
Looking at the pros and cons of oxyfuel cutting
Checking Out and Setting Up Oxyfuel Cutting Equipment
Examining oxyfuel cutting equipment
Deciding among different gas cylinder sizes
Setting up oxyfuel cutting equipment
Chapter 12 Ready, Set, Cut! Trying Out Plasma Arc Cutting and Oxyfuel Cutting
Exploring Plasma Arc Cutting
Slicing a straight line
Cutting a circle
Creating a bevel
Practicing Oxyfuel Cutting
Lighting the torch
Making a straight cut
Cutting out a circle
Taking on a beveled edge
Chapter 13 Exploring Special Weld Processes
Working Through the Basics of Welding with Gas
Taking a gander at gas cylinders
Looking at more gas welding equipment
Getting to work with gas welding
Discovering Brazing (Braze Welding)
Keeping a few brazing rules in mind
Giving brazing a try
Finding Out about Fusion Welding
Soldering On: Exploring Soldering
Following the rules of soldering
Understanding the two types of soldering
Trying the soldering process
Chapter 14 Exploring Pipe Welding
Delving into the Different Kinds of Pipe
Getting Down to Welding Steel Pipes
Getting set up and preparing the pipe
Making the tacks
Welding the pipes
Trying some other angles
Peeking at a Few More Types of Pipe Welding Joints
Keeping an Eye Out for Common Pipe Welding Defects
Chapter 15 Working with Cast Iron
Casting Light on the Three Most Common Types of Cast Iron
Gray cast iron
Malleable cast iron
Nodular cast iron
Getting the (Cast) Iron in the Fire: Welding Gray Cast Iron
Stick welding cast iron
Oxyfuel welding cast iron
Mig welding cast iron
Part 5 Putting Welding into Action with Projects and Repairs
Chapter 16 Two Welding Projects to Boost Your Welding Shop
Creating a Torch Cart
Gathering the materials
Acquiring the right steel pieces
Measuring and cutting pieces
Making the welds
Adding the wheels
Checking your welds
Picking out your paint
Fabricating Your Own Portable Welding Table
Rounding up your tools
Picking out the parts
Assembling the pieces
Ensuring smooth edges
Choosing your paint
Putting on the wheels
Chapter 17 Constructing a Campfire Grill
Fabricating a Campfire Grill
Getting your tools in order
Obtaining the proper steel pieces
Cutting the steel pieces to length
Welding the grill
Picking out your paint
Seasoning the cooking surface
Chapter 18 Fixin’ to Fix Things: Analyzing and Planning
Determining Whether Something Is Fixable
Planning a Repair Strategy
Identifying the metal and what it means for the repair
Deciding which welding process to use for your repair
Making and following your plan
Getting Ready to Make Repair Welds
Preparing your repair piece and work area
Gathering your equipment and tools
Selecting filler rods and electrodes
Considering Cracks
Part 6 The Part of Tens
Chapter 19 Ten Tools Every Welder Wants
4½-Inch Grinder
Hacksaw
Air Compressor
3⁄8-Inch Electric Drill
Wrench Set
Steel Sawhorses
Cutoff Saw
Bench Grinder
Bottle Jack
Toolbox
Chapter 20 (Not Quite) Ten Advantages of Being a Certified Welder
More Job Opportunities
Better Pay
More Chances for Advancement
Certification that Travels with You
Ability to Join a National Organization
Qualification in Specific Areas of Welding
Increased Confidence in Your Welding Skills
Listing in the American Welding Society Database
A Head Start on Additional Types of Welding Certification
Chapter 21 (Almost) Ten Welding Defects
Incomplete Penetration
Incomplete Fusion
Undercutting
Slag Inclusions
Flux Inclusions
Porosity
Cracks
Warpage
Spatter
Chapter 22 Ten Signs You’re Welding Correctly
The Weld Is Distributed Equally between Parts
The Slag or Shielding Material Doesn’t Stick to the Weld
No Holes or Irregularities on the Weld Surface
The Weld Is Tight
The Weld Is Leakproof
The Weld Has Full Penetration
The Weld Has No Undercutting
The Weld Has No Overlap
The Weld Meets Strength Requirements
You’re Safe and Healthy
Chapter 23 Ten Maintenance Tips for Your Welding Equipment and Shop
Checking on Your Hand Tools
Taking Care of Power Tools
Doing Basic Housekeeping in the Shop
Protecting Your Welding Helmet
Seeing to Stick Welding Machine Maintenance
Working on Maintaining Your Mig Welding Machine
Tuning Up Your Tig Welding Machine
Taking Care of Your Oxyfuel Equipment
Keeping Your Air Compressor Working
Drill Press Maintenance
Glossary
Index
EULA