1. Arc Welding Equipment

2. Welding Machines
AC – (alternating current) used for most agricultural arc welding jobs and has low purchase cost compared to other arc welders

3. Welding Machines
DC (direct current) are generator operated and can be used where regular electrical power is not available

4. Welding Machines
AC/DC – welders use a rectifier to change regular AC current to DC
These welders can be used as either AC or DC

5. Welding Machines
TIG (tungsten inert gas) welders have an electric power unit, a pressure reducing regulator, electrode holder, tungsten electrode, nozzle, cables and hoses, and a gas supply unit

6. TIG
The two gases used are helium and argon

7. TIG
The tungsten electrode is not consumed (burned) and there is no slag on the bead

8. TIG
TIG is good for welding stainless steel and aluminum because it is stronger and more free of corrosion than other welders

9. Welding Machines
MIG (metallic inert gas) welders are wire feed welders that use a consumable wire fed automatically through the torch and can be used in industries as an automatic welder

10. Welding Equipment
Helmet, leather gloves, leather aprons, leather welding jacket, and leather boots are for protection

11. Welding Equipment
Chipping hammer removes slag, and wire brush removes rust and dirt

12. Welding Equipment
Clamps and vise grip clamps are used to hold metal in place for welding

13. Electrodes
Electrodes are wire cores or rods usually covered in flux

15. Electrodes
Size is the diameter of the metal rod not including flux

16. Electrodes
Classification code system has a letter and four numbers such as E6011 or E6013

17. Electrodes
E6011 is the most commonly used electrode for welding farm projects because it can be used for all purpose welding of mild steel, has deep penetration, and can be used with both AC and DC welders

18. Electrodes
E6013 is a good general purpose electrode but only has medium penetration

19. Arc Welder
An electric arc welder is used to weld two pieces of metal by melting and joining the edges of each using an electrode to help fill the space between them

20. TIG Welder
TIG welders are best for welding aluminum and stainless steel

21. MIG Welder
MIG welders are the best welder for welding very thin metals

22. Shade 10
A shade 10 lens in a welding helmet protects the eyes of the person welding or the person watching someone weld

23. Chipping Hammer
A chipping hammer is used to remove the slag (crust) off a welded bead

25. Basic Arc Welding Procedure

26. Clean Metal
Metal should be cleaned before it is welded

27. Clean Metal
A grinder is the fastest way, but a wire brush or other methods may be used to remove paint, rust, dirt, or oil

28. Beveled
Metal more than ¼” should be beveled at a 30 degree angle and placed 1/16” to 1/8” apart before two pieces are welded together

29. Welding Joints
Butt – two pieces of metal lying in the same plane such as end-to- end or edge-to-edge in a flat position

30. Welding Joints
T – two pieces of metal placed together to form a T (two pieces at a 90 degree angle)

31. Welding Joints
A fillet weld is used to fuse the two pieces permanently

32. Lap
Two pieces of metal overlap each other

33. Corner
Two pieces of metal make a 90 degree corner

34. Edge
Two pieces placed parallel to one another or stacked on top of each other

35. Amperage Setting
Welding position, metal thickness, and electrode size are used to determine amperage setting

36. Amperage Setting
Amperage too low causes a narrow, high bead with poor penetration

37. Amperage Setting
Amperage too high caused a flat bead with excessive spatter

38. Amperage Setting
Correct amperage helps make a uniform bead with bead width and penetration depth equal to each other

39. Before Welding Before metal is welded,
it should be identified, cleaned and cut to correct size (if needed)

40. Electrode Sticks
If an electrode sticks to the metal, the electrode should be wiggled back and forth, or it should be released from the electrode holder

41. Electrode Size
The maximum thickness of the beveled edge of metal should be the same as the diameter of the electrode used to make the weld

42. Electrode Size
A 1/8” electrode for a 1/8” thick bevel

43. Adjust Amperage
Spatter and flat bead are caused by amperage that is too high

44. Adjust Amperage
A high narrow bead with poor penetration is caused by amperage that is too low

45. Strike and Arc
Tapping or scratching methods can be used to strike an arc (starts a weld)

46. Arc Length
Arc length should be the same as the diameter of electrode

47. Strong Weld
Many different electrode movements or weaves are used to make a bead

48. Strong Weld
Regardless of the movement used, the pattern should be uniform to make a strong weld

49. Travel Speed
If the travel speed is too fast, the welded bead is narrow